CN109396330A - The method for carrying out model casting using increasing material manufacturing - Google Patents
The method for carrying out model casting using increasing material manufacturing Download PDFInfo
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- CN109396330A CN109396330A CN201710698015.3A CN201710698015A CN109396330A CN 109396330 A CN109396330 A CN 109396330A CN 201710698015 A CN201710698015 A CN 201710698015A CN 109396330 A CN109396330 A CN 109396330A
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- Prior art keywords
- cavity plate
- digital
- analogue
- cavity
- instance sample
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
- B22C7/02—Lost patterns
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
Abstract
The method for increasing material technology model casting is utilized the present invention provides a kind of.On the one hand, this method comprises: creating the digital-to-analogue of construction set using the one or more software tools that can be executed on a computing device, which is imported into increasing material manufacturing equipment；According to digital-to-analogue, control increases material equipment and creates first instance sample；The first cavity plate is created using first instance sample as template, the first cavity plate of creation has a cavity defined substantially by first instance sample appearance profile；Second instance sample is created using the first cavity plate；It surrounds second instance sample and creates the second cavity plate；Utilize one casting of the second matrix manufacturing；And pass through refine castings production construction set.
Description
Technical field
The present invention relates to the methods for using increasing material manufacturing to carry out model casting.Further, the present invention relates to use to increase
Material manufacture carries out the building element in the method production architectural construction of model casting, which has highly complex geometry
Shape.
Background technique
Presently, there are a variety of methods for manufacturing three-dimensional (3D) solid articles (for example, building element).These methods generally may be used
Subtract material manufacture and increasing material manufacturing to be divided into.
Subtract material and be produced by and cuts away the material of a solid block continuously to construct 3D object.The manufacturing method can
More typically to use numerically-controlled machine tool (CNC) by manually cutting material.For example, can be reinforcing glass using CNC
Fiber concrete (GRFC) is by Milling Machining at simple 3D shape.Because its bending strength is poor, GRFC plate usually compares
Thickness, also not complicated 3D shape.
On the other hand, increasing material manufacturing, commonly referred to as 3D printing usually pass through the material continuously generated under control of the computer
Expect that (such as plastics, metal, concrete etc.) layer constructs 3D object.These 3D shapes almost can be by 3D digital-to-analogue or other electronics
Any shape and geometry that data format is formed.
For example, direct metal laser sintering (DMLS) is a kind of increases material manufacturing technology, three-dimensional structure is generated using laser beam
Part.DMLS system emits on laser beam to the bedding of metal powder, the point position in space that automatic aiming 3D digital-to-analogue defines, by by material
Material melts and welds together and manufacture stereoscopic member.By selecting material, DMLS can manufacture the 3D object of extremely complex shape
Body.Currently, the maximum volume of building supported is about 10.00in. × 10.00in. according to DMLS system state-of-the-art
× 8.70in, and DMLS is very expensive.Because of a typical building element, such as Side fascia, may have 3m x 2m (or
118in. × 79in.) greatly, obviously it has been more than that the maximum of DMLS can be supported to build volume, has been manufactured with DMLS for architectural construction
In building element (such as Side fascia) be unpractical.
Many other increases material manufacturing technologies can be used for the manufacture of 3D object.For example, molten copper infiltration (FDM) is a kind of
Increases material manufacturing technology is commonly used for production model, prototyping and products application.In the case of FDM, material adds at nozzle
Heat is extracted out from nozzle, is then deposited from level to level.The nozzle can move horizontally, vertical in each mew layer deposition aftertable
Move up and down.In addition, Stereolithography is a kind of by molding increases material manufacturing technology in layer, it is used to manufacture mould
Type, prototype, pattern and product component.SLA forms polymer by photopolymerization, and photopolymerization is that light promotes strand to be linked at
A process together.In addition, selective thermal sintering is another increasing material manufacturing method, thermal printhead heats temperature-sensitive is used
Molding powder last layer.After the completion of one layer, powder bed will be moved down, and have the roller of an automation to add new material layer,
The new material layer is sintered the next cross section to form model.However, due to the use of material be limited to plastics (such as
ABS, PVC etc.), resin and powder, therefore, above none of these methods can be used for directly printing building/outer wall material.
In consideration of it, needing to develop a kind of large scale construction set (such as lateral dimensions that can be manufactured for architectural construction
(long or wide) is at least more than 1 meter) new method, which has highly complex geometry.
Summary of the invention
The present invention provides a kind of methods of model casting, are a kind of for manufacturing the increasing material manufacturing side of building element
Method.Disclosed herein combination large scale 3D printing technique and cast molding technologies.Pass through the exposure of invention, large scale
Building element become can large-scale customization and price can bear, quick and inexpensive design complex building structure is made by the technology
Part is possibly realized.
On the one hand, the present invention provides the investment casting methods using increases material manufacturing technology.This method comprises: using counting
One or more software tools that calculating can be performed on machine equipment create the digital-to-analogue of a building building, and the digital-to-analogue is imported one
In increasing material manufacturing device；According to the digital-to-analogue, first entity sample is produced by controlling increasing material manufacturing equipment；Use first
Entity sample creates first cavity plate as template, which has one is determined by the surface profile of the first instance sample substantially
The cavity of justice；Second instance sample is produced using the first cavity plate；By surrounding the second instance sample, so that creation second is recessed
Mould；A casting is cast using the second cavity plate, and passes through refine castings production construction set.
In one embodiment, the digital-to-analogue of creation is divided into multiple digital-to-analogue portions according to the predefined boundary rule of the digital-to-analogue
Part, therefore, each adjacent digital-to-analogue part boundaries have complementary shape.
In one embodiment, the shape of the complementation includes linear, sinusoidal waveform, square waveform, zigzag and random saw
One of tooth form.
In one embodiment, creation first instance sample includes: to pass through control one or more according to the digital-to-analogue component
Increase the component that material equipment creates the first instance sample, each digital-to-analogue component defines a group of the first instance sample respectively
Part；The first instance sample is formed by combining those components.
In one embodiment, control increasing material manufacturing equipment includes that plastic material layer is used continuously to construct first entity
Sample.
In one embodiment, creation second instance sample includes: the injection hydrothermal solution material into the cavity of the first cavity plate；And
Keep the hydrothermal solution material cooling and solidifies in the cavity, to form second instance sample.
In one embodiment, to include fusing point may be cast as material (such as wax) lower than 100 DEG C to hydrothermal solution material.
In one embodiment, it includes: the second cavity plate of heating to certain temperature that casting is created in the second cavity plate, thus
It is melted in second instance sample in the second cavity plate, second instance sample is discharged from the second cavity plate, thus in the second cavity plate
One cavity of middle formation；Hydrothermal solution material is injected into the cavity of the second cavity plate, and fills up the cavity；Keep the hydrothermal solution material cooling simultaneously
A solid articles are formed by curing, the shape that shape and the digital-to-analogue of the solid articles define is almost the same；Then from the second cavity plate
The solid articles are displaced, that is, form casting.
In one embodiment, injection hydrothermal solution material includes injecting a kind of construction material that fusing point is much higher than 100 DEG C.
In one embodiment, construction material includes one of metal, glass, ceramics and concrete.
In one embodiment, refine casting includes needing to polish casting according to refine design.
In one embodiment, refine casting includes that one layer of protective layer for increasing its durability is applied to casting.
In one embodiment, creation first instance sample includes that creation and digital-to-analogue define the consistent 1:1 ratio of size
First instance sample.
In one embodiment, first instance sample has at least 1 meter of lateral dimension.
On the other hand, disclosed herein a kind of investment casting methods using increasing material manufacturing.This method comprises: using
The digital-to-analogue for the one or more software tools creation building element that can be performed in computer equipment, and digital-to-analogue is imported into increasing material manufacturing
In equipment, which includes multiple digital-to-analogue components, wherein the boundary of adjacent digital-to-analogue component has complementary shape.According to digital-to-analogue
Component, the component of first instance sample is created by controlling one or more increasing material manufacturing equipment, and each digital-to-analogue component is fixed respectively
Then one component of adopted first instance sample connects those components and forms first instance sample；Utilize first instance sample
The first cavity plate is created as template, the first cavity plate has a cavity defined substantially by the surface profile of first instance sample；
Second instance sample is created using the first cavity plate；By surrounding second instance sample, thus the second cavity plate of creation；It is recessed using second
Mould creates a casting；Pass through the refine castings production construction set.
In one embodiment, the shape of the complementation includes linear, sinusoidal waveform, square waveform, zigzag and random sawtooth
One of shape.
In one embodiment, controlling one or more increasing material manufacturing equipment includes, and a kind of situation is, one or
One component of multiple increasing material manufacturing equipment continuous use plastic material layer construction first instance samples.
In one embodiment, creation second instance sample includes: the injection hydrothermal solution material into the first cavity plate cavity；Make heat
Liquid material is cooling and is freezing together with the cavity, to form second instance sample.
In one embodiment, what hydrothermal solution material included fusing point lower than 100 DEG C may be cast as material (such as wax) and.
It in one embodiment, include: the second cavity plate of heating to certain temperature in the second recessed middle creation die casting, thus
It is melted in second instance sample in the second cavity plate, second instance sample is discharged from the second cavity plate, thus in the second cavity plate
One cavity of middle formation；Hydrothermal solution material is injected into the cavity of the second cavity plate, and fills up the cavity；Keep the hydrothermal solution material cooling simultaneously
A solid articles are formed by curing, the shape that shape and the digital-to-analogue of the solid articles define is almost the same；Then from the second cavity plate
The solid articles are displaced, that is, form casting.
In one embodiment, injection hydrothermal solution material includes injecting a kind of construction material that fusing point is much higher than 100 DEG C.
In one embodiment, construction material includes metal, glass, ceramics and concrete.
In one embodiment, refine casting includes needing to polish casting according to refine.
In one embodiment, refine casting includes that one layer of protective layer for increasing its durability is applied to casting.
In one embodiment, creation first instance sample includes the first of the size 1:1 ratio that creation is defined with digital-to-analogue
Entity sample.
In one embodiment, first instance sample has at least 1 meter of lateral dimension.
On the other hand, the invention discloses provide a kind of method of investment casting mold for creating an object.This method packet
Include: on the multiple digital sub-component models a to nonvolatile computer storage media of storage, each digital sub-component model is
The modeling of one part of object；Multiple physics sub-components, each physics are generated using at least one increasing material manufacturing equipment
Component is generated by consistent digital submodule type corresponding with the majority submodel.Using multiple physics sub-component as template
The first cavity plate is created, the first cavity plate has one to define almost the same cavity with the object appearance profile；It is created using the first cavity plate
Build second instance sample；By surrounding the second instance sample, thus second cavity plate of creation.
In one embodiment, this method further comprises, before creating the first cavity plate, by the majority physics
Sub-component links together, thus the appearance profile of basic definition object.
In one embodiment, the boundary tool of two adjacent physics sub-components in multiple physics sub-components
Well-regulated pattern shape.
In one embodiment, the boundary tool of two adjacent physics sub-components in multiple physics sub-components
There is irregular pattern shape.
In one embodiment, multiple physics sub-components described in connecting include will be in multiple physics sub-components
Two adjacent physics sub-components are closely together.
In one embodiment, the first cavity plate of creation includes: the multiple submodule tools of creation, each submodule tool utilizes corresponding
Physics sub-component is as subtemplate, and the physics sub-component is from multiple physics sub-components；Link those submodules tool structure
At the first cavity plate.
Detailed description of the invention
One embodiment according to the present invention, Fig. 1 are a flow charts, illustrate model casting production construction set
Method.
One embodiment according to the present invention, Fig. 2 illustrate the process of production Side fascia, the process in figure are as follows: 1,
CAD designs your any thinkable shape on computers；2, plastics print: large scale 3D printer uses
1:1 ratio, size if necessary have been more than the print range of printer, in such cases, multiple monolithics can be sticked to
Together；3, it is wax modeling: creates a cavity plate for wax；4, wax pattern: it can be used repeatedly for the model；5, it removes wax: using thermal resistance
Material is that wax creates a mould, and then heating the mould makes wax melt and flow out；6, fall material: hydrothermal solution material is poured into the mould；
7, finished product: finished product cast can be processed by shot blasting according to the design needs；8, high-performance integrates wall: finished product cast is used to be wall
Plate, high-performance integrate a part of wall.
One embodiment according to the present invention, Fig. 3 illustrate the process of production adaptive connection head, the process in figure
Are as follows: 1, CAD: the adaptive connection head designed for connecting 3D Side fascia and structural wall；2, plastics print: big
Size 3D printer uses 1:1 ratio；3, it is wax modeling: creates a cavity plate for wax；4, wax pattern: the model can be repeatedly
It uses；5, it removes wax: the use of heat proof material being that wax creates a mould, then heating the mould makes wax melt and flow out；6, material is poured liquid
Material: hydrothermal solution material is poured into the mould；7, finished product: finished product cast can be processed by shot blasting according to the design needs；8, it installs: should
Adaptive connection head can adapt to complicated surface, connect the Side fascia of complicated shape.
One embodiment according to the present invention, Fig. 4 are illustrated with the process of free form production complexity 3D structure, figure
In process are as follows: 1, CAD: design the construction package of complicated shape；2, plastics print: large scale 3D printer,
Use 1:1 ratio；3, it is wax modeling: creates a cavity plate for each single-piece；4, wax pattern: it can be used repeatedly for the model；
5, it removes wax: the use of heat proof material being that wax creates a mould, then heating the mould makes wax melt and flow out；6, material is poured liquid: to
Hydrothermal solution material is poured into the mould；7, finished product: finished product cast can be processed by shot blasting according to the design needs；8, it installs and does final
Refine: the single-piece of a large amount of construction packages is assembled, connect, then refine become finished product.
Embodiment according to the present invention, Fig. 5 illustrate the typical boundary shape of two adjacent digital-to-analogue components, should
Digital-to-analogue is defined by the 3D solid articles produced.
Specific embodiment
The present invention provides a kind of methods for carrying out model casting using increasing material manufacturing, and for producing, such as large scale is built
Build component (such as with large scale, such as length or wide at least more than 1 meter).The method disclosed according to the present invention, it is large-sized to build
Build component become can large-scale customization and price can bear.
In general, large-scale customization is the product for mass customization, and the product of the mass customization eliminates
The rigidity of traditional mass production method.Design or production process can be easily varied without increasing additional production cost, very
To after the line that puts into production.With the appearance as 3D printing digital tool, the somewhat complex design with a steps and component up to a hundred
It can be reduced to seldom component with production line (such as car engine), to simplify and reform design production process.
Casting generally involves the step of hydrothermal solution material (such as molten metal) is toppled over into the mold for have cavity.So
Afterwards, the hydrothermal solution is cooling and is set in the cavity of mold, thus the solid articles of shape needed for being formed.Finally, the solid articles
It is displaced from mold.The shape of mold can be by disposable pattern definition (such as waxed sample).This technology is usual
Referred to as model casting or lost wax casting.Disposable pattern can be hand engraving wax stone and be made, or by machining
Pattern punching block in injection wax material be made.Pattern is produced from pattern punching block (it is consistent with waxy three-dimensional)
Come, then melts or burn up from mold.Therefore, pattern has the shape for needing to complete component.For example, with reference to July 4 in 1989
The United States Patent (USP) No.4 of day authorization, 844,144, which is write by black phenanthrene et al., and full content is cited.
One embodiment according to the present invention, Fig. 1 are a flow charts, illustrate model casting production construction set
Method.One embodiment according to the present invention, Fig. 2 illustrate the process of production Side fascia.It is for clarity and simple
Illustrate, Fig. 1 and 2 will be discussed simultaneously below.According to Fig. 1 and 2, in step 110, number is created according to the 3D solid articles to be produced
Mould 112.One or more computer packages creations, such as cad tools (CAD) can be used in digital-to-analogue 112,
And it is stored in computer memory device 10 with electronic file form appropriate.In an alternative embodiment, digital-to-analogue 112 can pass through
3D scans artistical hand engraving works creation.
In one embodiment, digital-to-analogue 112 can use cross-platform method design, for example, utilizing compound cad tools.
Typically, architectural design is theoretical (NURBS) based on non-uniform rational B-spline, Parameterized Software (such as Rhinoceros 3D ring
The CATIA of the Grasshopper plug-in unit or Dassault Sys of America that are run under border).NURBS is one and is commonly used to computer and draws
The mathematical model of figure, for generating or presenting curve or curved surface.In Parameterized Software, the surface of 3D model can be by mathematics public affairs
Formula definition, the parameter by changing formula adjust the surface of 3D model.
Embedding plate is that big complicated building body is resolved into the process that can build baseboard (such as 1 square metre).However,
There is no panel characteristic in software-based NURBS.Moreover, subdivision software in, such as autodesk, inc. Maya software and
The Modo software of Luxology company, is also generally not used in building industry.Therefore, it is provided simultaneously with Parameterized design software (example
Such as Grasshopper) and the characteristics of close classification software (such as Modo), one kind is based on segmenting geometric perfect working method
It is developed.
In one embodiment, segmented using based on subdivision or Catmull-Clark algorithm software (such as Maya or
Modo), different building panels is created by digitlization in the form of a grid (such as quadrangle or square net).Grid is 3D text
Minimum unit in part because it in three-dimensional system of coordinate (such as rectangular coordinate system, cylindrical coordinate system or spheric coordinate system) only
Indicate vertex.Catmull-Clark subdivision is a technology applied to computer graphics, can be created by subdivision curved surface model
The sliding curved surface in Jianping.Grid is imported into the Parameterized Software as Rhino software to go to rebuild.Then, parametric software (such as
Grasshopper in), grid vertex is instructed to as key parameter.In one embodiment, each in Parameterized Software
A grid still maintains as a grid, without being converted to mathematical formulae.
In one embodiment, it moves by the vertex (for example, using attraction person's point) of state modulator, to allow not
Same variation and metamorphosis.It is, the digitized plate of grid configuration can change as different shapes, and each number
Word plate may finally have different shapes, rather than share similar plate (such as a large amount of customizations).Final grid is by again
It imports among the software (such as Modo) based on close classification, finally adjusts grid and be changed into smooth organic shape.Final is thin
Divide geometry that there is smooth organic shape, then can export becomes the mathematics format pre-defined, for example, NURBS,
" .OBJ, " and " .STL ", can be importing directly into 3D printer equipment and be further processed.
Also with reference to Fig. 1 and 2, in 120 steps, digital-to-analogue 112 is transmitted or is imported in 3D printing equipment 20 for creating
First instance sample 122, almost the same (such as the 1:1 ratio of the size and shape that first instance sample 122 and digital-to-analogue 112 define
Example).Based on digital-to-analogue 112, by being continuously superimposed multilayer 3D printing material, the 3D printing equipment 20 after programming creates first instance
Sample 112.In one embodiment, the 3D printing material of first instance sample 122 includes hard plastics.It should be noted
It is that, according to the 3D printing technique used, for FDM printer, the raw material of first instance sample 122 may include polylactic acid
(PLA) or acrylonitrile-butadiene-styrene copolymer (ABS), for SLA printer, the raw material of first instance sample 122 can
Including resin.
In a particular embodiment, the 3D object that digital-to-analogue 112 defines may cannot use existing 3D printing equipment 20 greatly very much
Carry out 3D printing.Therefore, the 3D printing for carrying out single batch to first instance sample 122 is difficult to realize.It therefore, can be by number
Word model 112 divides for multiple portions, and each part is printed with 3D printing equipment 20.These parts can be used as first instance
The component of sample 122 is printed by single 3D printing equipment 20.For example, these components can pass through multiple 3D printings respectively
Equipment 20 simultaneously, continuously prints, and certainly, the component of dispersion can also print in any other suitable manner
Come.Then, the component of 3D printing, which combines, can form complete first instance sample 122.According to for producing the
The component of the material property of one entity sample 122, first instance sample 122 can be assembled by any method appropriate,
Such as punching press, mechanical fasteners, bonding, welding, hot melt.
In order to respectively create the component of first instance sample 122, executable software package can be used and be divided into digital-to-analogue 113
Multiple components, for example, the various components of each component and first instance sample 122 correspond on computer 10.Digital-to-analogue 112
Each component can be generated according to original digital-to-analogue 122, and be transferred to or imported and create the in one or more 3D printing equipment
The corresponding component of one entity sample 122.
In some embodiments, the boundary set in advance according to digital-to-analogue 112 is regular, and the executable software package on computer 10 is used
In the multiple components for generating digital-to-analogue 112.Therefore the adjacent component of digital-to-analogue 112 can form the boundary of shape complementation.According to this hair
Bright embodiment, Fig. 5 illustrate the typical boundary shape of two adjacent components 512A and 512B in digital-to-analogue 112.Two in digital-to-analogue 112
The boundary of adjacent component 512A and 512B can be defined in any suitable manner.In some embodiments, the boundary
Shape can be specifically designed as the shape 502,504 (such as linear, sinusoidal waveform, square waveform etc.) or irregular shape of rule
Shape 506 (such as a random zigzag).In some embodiments, these boundaries can mutually link closely.In some embodiments
In, if it is desirable, each component of first instance sample 122 can be obtained according to the respective component of corresponding digital-to-analogue 112
, it includes the boundaries for being designed specifically to shape.The boundary for being designed specifically to shape can increase by two phases of first instance sample 122
The bonding area of adjacent component, to increase the structural strength of combination.In other embodiments, when generating the component of digital-to-analogue 112,
According to preset type of attachment, for example, splice joint, boundary rule can define two adjacent components of digital-to-analogue 112
Side.
In certain embodiments, according to initial setting on computer 10,3D printing equipment 20 can be received completely
Digital-to-analogue 112.Before 3D printing first instance sample 122, as described above, it can be performed using in 3D printing equipment 20
Software package, the boundary rule applied according to the digital-to-analogue 112 that receives, digital-to-analogue 112 can be converted to multiple by 3D printing equipment 20
Component.
In step 130, the first cavity plate 132 is created using first instance sample 122 as template, makes the first cavity plate 132
One cavity of middle formation.The outer shape of the cavity of first cavity plate 132 and the surface profile of first instance sample 122 are essentially identical.At this
In the case of kind, multiple components of first instance sample 122 are respectively by 3D printing, according to multiple groups of first instance sample 122
Respective one of part, multiple first cavity plates 132 are created.In that case, multiple first cavity plates 132 can be connected to
The essentially the same cavity for having and being defined by digital-to-analogue 112 for a large-sized cavity plate, the cavity plate.In order to reduce degree of roughness
The boundary of multiple first cavity plates 132 can be polished and refine.
In order to facilitate cavity is used, one or more input channels 134 can introduce the first cavity plate 132.Input channel 134
Can drill formation or other suitable methods on the first cavity plate 132.Silica gel material can be used in first cavity plate 132, the silica gel
Material is that one kind is usually used in casting wax mould material material or usable rubber, which is a kind of cheaper optional material, or
Other alternative materials can be used.In some embodiments, the material melting point of the first cavity plate 132 be higher than hydrothermal solution material 142 (
It is introduced in step 140).
In step 140, by the input channel 134 on the first cavity plate 132, hydrothermal solution material 142 is injected the first cavity plate
In 132 cavity, to be full of entire cavity.In one embodiment, hydrothermal solution material includes organic material (for example, wax), should
Material can form hydrophobic and plastic solid at room temperature.In one embodiment, which has 40 DEG C and arrives
80 DEG C of fusing point or fusing point is lower than 100 DEG C.Hydrothermal solution material 142 is cooled and is solidificated in the cavity of the first cavity plate 132, from
And form second instance sample 144 (or wax duplicate).Then, second instance sample 144 is removed from the first cavity plate 132.
In step 150, the second cavity plate 152 is created by surrounding second instance sample 144.In one embodiment,
Two cavity plates 152 prepare (such as ceramics, gypsum, sand etc.) by heat proof material, and include an output channel 154 and an input
Channel 156.In certain embodiments, input channel 156 and output channel 154 may be same.In one embodiment, very
Extremely when temperature is higher than 1000 DEG C, heat proof material possibility or solid state.According to the material property being cast is determined the
The heat proof material of two cavity plates 152.The fusing point of the heat proof material of second cavity plate 152 is necessarily considerably above the molten of the material that will be cast
Point.For example, therefore aluminium can be cast with about 660 DEG C of low melting point in the mould of most of material types.However, stainless
Steel has 1300 DEG C of fusing point, higher than 1200 DEG C of the fusing point (about 1200 DEG C of operational temperature) of gypsum.Therefore, stainless steel cannot
It is cast in gypsum mold, it is necessary to be cast in there is more dystectic mold, such as husky mould.
It should be noted that in certain embodiments, not needing implementation steps 130 and 140, the second cavity plate 152 can be straight
It connects and is prepared by first instance sample 122.It is, can print material (such as plastics or wax), first instance sample 122 by 3D
, to directly prepare the second cavity plate 152, step 130 and 140 may can be saved so directly by 3D printing at enough large scales.
It should also be appreciated that step 130 and 140 may need to implement repeatedly in other specific embodiments.
In a step 160, certain temperature is arrived by the second cavity plate 152 of heating, to make the second reality in the second cavity plate 152
Body sample 144 liquefies.As a result, by output channel 154, liquefied second instance sample 144 flows and to be discharged second recessed
Mould 152, to form a cavity in the second cavity plate 152.The 144 surface profile base of shape and second instance sample of the cavity
This is consistent.
In step 170, by input channel 156, hydrothermal solution material 172 is injected in the cavity of the second cavity plate 152, thus
Fill up entire cavity.Then the cooling and solidifying of hydrothermal solution material 172 is at a solids essentially the same with the shape of the definition of digital-to-analogue 112
Part 174.In order to be further processed, which is displaced from the second cavity plate.In various embodiments, hydrothermal solution material
Material 172 may be with dystectic construction material, for example, metal (such as silver, gold, brass, bronze, tin, aluminium etc.), glass,
Ceramics, concrete or the like.In one embodiment, the melting range of construction material is about 200 DEG C to 2000 DEG C, Huo Zheming
It is aobvious to be higher than 100 DEG C.It is worth noting that, the fusing point of hydrothermal solution material 172 has to be mostly used thermal resistance material significantly lower than the second cavity plate 152
The fusing point of material.
In step 180, solid articles 174 are polished according to finished product needs or are coated a guarantor to increase durability
Sheath (such as one or more layers anticorrosion paint), to form finished product 182.In one embodiment, finished product 182, which can be, is attached to
The Side fascia of exterior wall assembly line 184 is attached it in building structure by table 186.Technology according to the present invention, Side fascia can
To be made into complicated 3D structure and pattern, while still having the function of protection building.
An embodiment according to the present invention, Fig. 3 illustrate the process of manufacture adaptive connection head.Fig. 3 present process with
Fig. 2 is similar, has only changed Side fascia into adaptive connection head.Adaptive connection head is a structural detail, it is used for will be outer
Wallboard is connected on structural wall.Using the method for the present invention, highly complex adaptive connection head can be created, therefore, according to not
Same scene, adaptive connection head can adapt to the different situations on complex building surface.
With reference to Fig. 3, in the step 310, using one or more cad tools, one or more is adaptive for building
Connector is answered by digitisation to be designed to digital-to-analogue 320.In step 320, digital-to-analogue 312 imports greatly in a manner of layer by layer
It is produced in the 3D printer of size, 322 size of first instance sample is consistent with design size (such as 1:1 ratio).Implement one
In example, first instance sample 322 includes hard plastics.In a step 330, the first cavity plate 332 is created to have one
The cavity defined by first instance sample 322.In step 340, fluent material (such as wax) 342 is injected in the cavity, from
And prepare second instance sample 344.In one embodiment, real comprising may be cast as the second of material (such as wax or may be cast as plastics)
Body sample 344 replicates first instance sample 322.
Referring again to FIGS. 3, in step 350, by surrounding one or more second instance samples 344, using heat-resisting material
Material the second cavity plate 352 of preparation, and heating makes to may be cast as the outflow of material duplicate, to leave a cavity in the second cavity plate 352.
In step 360, hydrothermal solution material (such as metal) 362 injects in the cavity of the second cavity plate 352, then cools down and solidifies.In step
In rapid 370, cured casting 372 is displaced from the second cavity plate 352, then, is polished or is coated, so that is be designed is adaptive
Connector 382 is answered, so that it be made to meet the needs of refine design or durability.In step 380, adaptive connection head 382 is used
In connection 3D Side fascia 384 and structural wall 386, the two be the construction set of complicated shape.In one embodiment, adaptively
Connector 382 in some dimension (such as long or wide) less than 1 meter.
It can be manufactured in this way in view of adaptive connection head, according to gravity and/or the angle of lateral force, exterior wall is connected to building
The structural detail of metope can be adjusted arbitrarily.For example, Side fascia can extend into roof and be more than the scope of ceiling.It needs to infuse
Meaning is that same method can be applied to other construction sets, for example, building structure and indoor design.
Fig. 4 illustrates the process that method of the invention according to figure 1 freely manufactures complexity 3D structure.Shown in Fig. 4
Process it is similar with shown in Fig. 2 and 3, only complexity 3D construction package is instead of Side fascia and adaptive connector.
With reference to Fig. 4, in step 410, using one or more cad tools by complicated 3D structure and component numerical digit herein
Change is designed to digital-to-analogue 412.According to the horizontal nature (such as column) of 3D structure, which is divided into longest dimension no more than 4
The different components of rice.At step 420, digital-to-analogue 412 is injected into one or more 3D printers and produces, and one layer connects one layer,
The size of first instance sample 422 is consistent with design size (such as 1:1 ratio).In one embodiment, first instance sample 422
It all include hard plastics including first structure trunk sample 422A and first structure branch sample 422B.In step 430
In, the first one or more cavity plates 432 is created, each cavity plate 432 is with one by corresponding first structure trunk sample
The cavity that 422A and first structure branch sample 422B are defined.In step 440, fluent material 442 (such as liquid wax) injection the
In the cavity of one cavity plate 432, to prepare second instance sample 444, including the second structure trunk sample 444A and the second structure
Branch sample 444B.In one embodiment, comprising may be cast as the second structure trunk sample 444A and second of material (such as wax)
Structure branch sample 444B replicates first structure trunk sample 422A and first structure branch sample 422B.
Referring again to Fig. 4, in step 450, one or more second cavity plates 452 are prepared using heat proof material, each
Second cavity plate 452 surrounds one or more second samples 444, and then heating makes to may be cast as duplicating material outflow, thus second
A cavity is left in cavity plate 452.In step 460, hydrothermal solution material (such as metal) 462 is by the sky of the second cavity plate 452 of injection
In chamber, cooling simultaneously solidifies.In step 470, cured casting 472 is displaced from the second cavity plate 452, then carry out polishing or
Coating, so that the construction package (such as structure trunk 472A and structure branch 472B) of design be made to meet refine design and durability
Needs.In step 480, structure trunk 472A and structure branch 472B link together (such as passing through welding), so as to shape
The finished product needed at complicated 3D structure 482.In one embodiment, complicated 3D structure 482 can be in some dimension (such as high)
More than 1 meter.
To sum up, this field have general technical ability people can find method of the present invention be it is beneficial, because of building group
Part can be with free shape and highly customized mode carries out 3D printing, and can choose material, and can be suitable for
Complete structure.Building no longer needs to be designed or build rectangular and/or box type stacking.The manufacturing constraints of Architectural Elements
It reduces, such as front, construction and inner space allow more creative and diversity.Side fascia is no longer rectangular slab ---
It can be the 3D shape with complicated decoration.Constructional column no longer needs to be simple cylindricality.With complex form and shape
Construction set, size about 4m × 3m × 3m, can be greater or lesser, can be constructed in accordance.Therefore, it is led in building
Domain can establish new standard.For example, space frame can be designed with complicated details and decoration, and price and efficiency
It is all similar to the prior art.
In addition, method of the invention be in 3D printing Side fascia (with plastics or other materials) it is beneficial, can pass through
Welding or other modes connect into large-sized mold, to create cavity plate for final casting.3D printing is eliminated in this way to deposit
Size limitation.
In terms of material, the convention of characteristic building is to build front using cast iron, glass or stone.Once mold and/or
Plastic sample prepares, so that it may Reusability.According to the present invention, with lower Cost Design and construction, preferably building becomes
It may.For using metal, however it is not limited to which facade or interior wall can be applicable to other constructions, such as fence
Or other construction sets.In building trade, the size of existing 3D printing is used only for less than 0.1 stere
Small articles, such as door handle.
Moreover, make using traditional 3D printing technique very expensive.For example, printing one using DMLS technology
Object needs 24 hours, and is not easy to repeat.According to the present invention, 3D printing technique is no longer limited by size, and can be with
It is more economical.
According to the present invention describe and define purpose, it is noted that text in may use definition degree term (such as
" substantially ", " slightly ", " about ", " similar " etc.) the intrinsic degree that represents is uncertain, may be for quantitative
Compare, numerical value, measurement or other statements.These degree terms also are likely used for expression degree, and quantitative statement may be with reference
It provides different (such as about 10% or less), but not leads to the change of main body basic function because of disputable.It removes
Non- separately to have statement, according to degree term, any numerical value in this specification is all revisable, therefore reflects themselves
It is uncertain.
Although detailed herein, various embodiments of the present invention have been described, such as additional without departing from disclosed by the invention
In the spirit and scope of claims state, this field has the comprehensible variation appropriate of the personnel of general technology and other realities
Apply example.
Claims (35)
1. the method for carrying out model casting using increasing material manufacturing, which is characterized in that this method comprises:
Using the digital-to-analogue for the one or more software tools creation construction set that can be executed on a computing device, then by the number
Mould is imported into an increasing material manufacturing equipment；
According to the digital-to-analogue, controls the increasing material equipment and create a first instance sample；
Create one first cavity plate using the first instance sample as template, first cavity plate of creation have one substantially by this
The cavity that one entity sample appearance profile defines；
A second instance sample is created using first cavity plate；
It surrounds the second instance sample and creates one second cavity plate；
Utilize one casting of the second matrix manufacturing；
And pass through the refine castings production construction set.
2. the method as described in claim 1, which is characterized in that the digital-to-analogue of creation is according to the predefined boundary rule of the digital-to-analogue
It is divided into multiple digital-to-analogue components, therefore, each adjacent digital-to-analogue part boundaries has complementary shape.
3. method according to claim 2, which is characterized in that the shape of the complementation includes at least linear, sinusoidal waveform, square wave
One of shape, zigzag and random zigzag.
4. method according to claim 2, which is characterized in that creating the first instance sample includes:
According to the digital-to-analogue component, the components of the first instance sample are created by the one or more increasing material equipment of control, each
Digital-to-analogue component defines a component of the first instance sample respectively；The first instance sample is formed by combining these components.
5. the method as described in claim 1, which is characterized in that controlling the increasing material manufacturing equipment includes that plastics material is used continuously
The bed of material constructs first entity sample.
6. the method as described in claim 1, which is characterized in that creating the second instance sample includes: to first cavity plate
Hydrothermal solution material is injected in cavity；And keeps the hydrothermal solution material cooling and solidify in the cavity, to form the second instance sample.
7. method as claimed in claim 6, which is characterized in that the hydrothermal solution material includes the castable producing material that fusing point is lower than 100 DEG C
Material.
8. the method for claim 7, which is characterized in that it includes wax that this, which may be cast as material,.
9. the method as described in claim 1, which is characterized in that producing the casting in second cavity plate includes:
Second cavity plate is heated to certain temperature, so that the second instance sample be made to be melted in second cavity plate, by this
Two entity samples are discharged from second cavity plate, to form a cavity in second cavity plate；
Hydrothermal solution material is injected into the cavity of second cavity plate, and fills up the cavity；
Keep the hydrothermal solution material cooling and is formed by curing a solid articles, the shape base that the shape of the solid articles and the digital-to-analogue define
This is consistent；
Then the solid articles are displaced from second cavity plate, that is, forms the casting.
10. method as claimed in claim 9, which is characterized in that injecting the hydrothermal solution material includes injecting a kind of fusing point to be much higher than
100 DEG C of construction material.
11. method as claimed in claim 10, which is characterized in that the construction material includes at least metal, glass, ceramics and mixes
One of solidifying soil.
12. the method as described in claim 1, which is characterized in that the refine casting includes the needs according to refine design to this
Casting is polished.
13. the method as described in claim 1, which is characterized in that refine casting includes applying one layer to the casting to increase its resistance to
The protective layer of long property.
14. the method as described in claim 1, which is characterized in that creating the first instance sample includes that creation and the digital-to-analogue are fixed
The first instance sample of the adopted consistent 1:1 ratio of size.
15. method as claimed in claim 14, which is characterized in that the first instance sample has at least 1 meter of lateral dimension.
16. the method for carrying out model casting using increasing material manufacturing, which is characterized in that this method comprises:
Using the digital-to-analogue for the one or more software tools creation construction set that can be executed on a computing device, then by the number
Mould is imported into an increasing material manufacturing equipment, which includes multiple digital-to-analogue components, wherein the boundary of adjacent digital-to-analogue component has
Perfect shape.
According to those digital-to-analogue components, the component of a first instance sample is created by controlling one or more increasing material manufacturing equipment,
Each digital-to-analogue component defines an independent component of the first instance sample, then combine those components formed this first
Entity sample；
Create one first cavity plate using the first instance sample as template, first cavity plate of creation have one substantially by this
The cavity that one entity sample appearance profile defines；
A second instance sample is created using first cavity plate；
It surrounds the second instance sample and creates one second cavity plate；
Utilize one casting of the second matrix manufacturing；
And pass through the refine castings production construction set.
17. the method described in claim 16, which is characterized in that the shape of the complementation includes linear, sinusoidal waveform, square wave
One of shape, zigzag and random zigzag.
18. the method described in claim 16, which is characterized in that control one or more increasing material manufacturing equipment packets
It includes, a kind of situation is that one or more increasing material manufacturing equipment continuous use plastic material layers construct the one of the first instance sample
A component.
19. the method described in claim 16, which is characterized in that creating the second instance sample includes: to first cavity plate
Cavity in inject hydrothermal solution material；And keeps the hydrothermal solution material cooling and solidify in the cavity, to form the second instance sample
This.
20. method as claimed in claim 19, which is characterized in that the hydrothermal solution material includes that fusing point may be cast as lower than 100 DEG C
Material.
21. method as claimed in claim 20, which is characterized in that it includes wax that this, which may be cast as material,.
22. the method described in claim 16, which is characterized in that producing the casting in second cavity plate includes:
Second cavity plate is heated to certain temperature, so that the second instance sample be made to be melted in second cavity plate, by this
Two entity samples are discharged from second cavity plate, to form a cavity in second cavity plate；
Hydrothermal solution material is injected into the cavity of second cavity plate, and fills up the cavity；
Keep the hydrothermal solution material cooling and is formed by curing a solid articles, the shape base that the shape of the solid articles and the digital-to-analogue define
This is consistent；
Then the solid articles are displaced from second cavity plate, that is, forms the casting.
23. method as claimed in claim 22, which is characterized in that injection hydrothermal solution material includes injecting a kind of fusing point to be much higher than
100 DEG C of construction material.
24. method as claimed in claim 23, which is characterized in that the construction material includes at least metal, glass, ceramics and mixes
One of solidifying soil.
25. the method described in claim 16, which is characterized in that the refine casting includes the needs according to refine design to this
Casting is polished.
26. the method described in claim 16, which is characterized in that refine casting includes applying one layer to the casting to increase its resistance to
The protective layer of long property.
27. the method described in claim 16, which is characterized in that creating the first instance sample includes that creation and the digital-to-analogue are fixed
The first instance sample of the adopted consistent 1:1 ratio of size.
28. method as claimed in claim 27, which is characterized in that the first instance sample has at least 1 meter of lateral dimension.
29. the method for creating the investment casting mold of an object, which is characterized in that this method comprises:
It stores on multiple digital sub-component models a to nonvolatile computer storage media, each digital sub-component model is
The modeling of one part of the object；
Multiple physics sub-components are generated using at least one increasing material manufacturing equipment, each physics sub-component is by a with the majority
The almost the same digital submodule type of submodel generates；
The first cavity plate is created using multiple physics sub-component as template, the first cavity plate has one to define with the object appearance profile
Almost the same cavity；
Second instance sample is created using first cavity plate；
By surrounding the second instance sample, to create the investment casting mold.
30. method as claimed in claim 29, which is characterized in that this method further comprises, create first cavity plate it
Before, the majority physics sub-component is linked together, thus the appearance profile of the basic definition object.
31. method as claimed in claim 30, which is characterized in that two adjacent in multiple physics sub-components
The boundary of physics sub-component has well-regulated pattern shape.
32. method as claimed in claim 30, which is characterized in that two adjacent in multiple physics sub-components
The boundary of physics sub-component has irregular pattern shape.
33. method as claimed in claim 30, which is characterized in that multiple physics sub-components described in connecting include will be described
Adjacent two physics sub-component in multiple physics sub-components is closely together.
34. method as claimed in claim 29, which is characterized in that creating first cavity plate includes:
Multiple submodule tools are created, using corresponding physics sub-component as subtemplate, which comes each submodule tool
From in multiple physics sub-components；
It connects these submodules tool and constitutes the first cavity plate.
35. one has the increasing material manufacturing equipment of software package executable on a computing device, which is characterized in that utilize the software
Packet, the increasing material process equipment are arranged to the related digital-to-analogue of the threedimensional solid object that can receive be processed, by applying one
Pre-set boundary rule, is converted to multiple digital-to-analogue components for the digital-to-analogue, each digital-to-analogue component respectively with threedimensional solid
One components of object are corresponding, which, which further matches, postpones, the finger defined according to the digital-to-analogue component
It enables, removes a corresponding components of the manufacture at least threedimensional solid object layer by layer.
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Application publication date: 20190301 |