CN109843591A - 形成3d物体的方法 - Google Patents

形成3d物体的方法 Download PDF

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CN109843591A
CN109843591A CN201780063158.5A CN201780063158A CN109843591A CN 109843591 A CN109843591 A CN 109843591A CN 201780063158 A CN201780063158 A CN 201780063158A CN 109843591 A CN109843591 A CN 109843591A
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史蒂文·卡米莱里
拜伦·肯尼迪
托比·杰瑞特
莱伊尔·恩伯里
塞尔文·拉维恩
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Yifuren Technology Intellectual Property Private Ltd
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Abstract

一种形成3D物体的方法，包括参照定义物体3D形状参数的数据运行控制装置，使控制装置：使用所述数据控制涂布装置将材料喷涂在基板上，以逐步施加的层构建物体，其中至少部分层具有初始的向内渐缩的外边缘；及对于至少部分这样的层，使所述控制装置使用所述数据移动所述涂布装置以采用喷涂材料来填充锥体。

Description

形成3D物体的方法
技术领域
本发明涉及一种由喷涂材料形成3D物体的方法。
背景技术
众所周知，通过3D打印的方式将金属粉末从喷嘴冷喷涂到基板上，可以形成3D物体。例如，J Pattison等人在《International Journal of Machine Tools andManufacture》第47卷第3-4期，2007年3月，第627-63页中对此作了概述。采用许多已知的技术，喷涂材料一般呈大体圆锥状沉积。这导致最终的3D物体的边具有不需要的锥度。例如，这使得将物体分层喷涂变得不太可行，因为锥度效应使得每一层的面积都小于前一层。换句话说，锥度从一层传递到另一层。本发明的优选实施例的目的是至少在某种程度上解决这一问题。虽然这适用于优选实施例，但应理解，本发明的目的本身只是提供一种有用的选择。因此，适用于优选实施例的任何优势或限制不应理解为对更广泛表达的任何权利要求范围的限制。
在本文件中，有关特征或步骤组合的术语“包含”不应被视为排除存在其他特征或步骤的选择。该术语不应作限制性的解释。
发明内容
根据一个方面，本发明涉及一种形成3D物体的方法，包括参照定义物体3D形状参数的数据运行控制装置，使得所述控制装置：
使用所述数据控制涂布装置和/或基板支架，使喷涂材料先喷在所述基板上，再喷在部分成形后的物体上，以逐步施加的层构建物体，其中至少有部分层具有初始向内渐缩的外表面；以及
对于至少部分这样的层使所述控制装置使用所述数据使所述涂布装置采用喷涂材料填充锥体。
可选地，喷涂是冷喷涂，并且可以含有金属粉末。
可选地，填充所述锥体涉及所述控制装置：
根据喷涂特性计算所述锥体的参数；
计算适用于填充所述锥体的所述涂布装置和所述锥体之间的角度；以及
使所述涂布装置和锥体成所述角度，并使所述涂布装置将喷涂材料喷涂到所述锥体上。
可选地，所述数据在一系列层(例如概念切片)方面定义所述3D物体，并且所述控制装置使用下一层的预定义参数来控制用于喷涂填充所述锥体的所述涂布装置和锥体之间的所述角度。
可选地，表面扫描仪在构建物体时重复测量物体，并且所述控制装置使用测量结果来调节所述物体(当部分成形时)和所述涂布装置的相对位置，和/或所述喷嘴的喷涂参数，以提高形状参数和完成后的物体之间的匹配精度。
一种形成3D物体的方法，包括参照数据运行计算机化控制器，所述数据在概念切片方面定义物体的3D形状参数，使控制器：
使用所述数据控制涂布装置于基板上在相邻线处喷涂包括金属粉末的材料，以用与所述切片相对应的逐渐施加的层来构建所述物体，其中至少部分层具有初始向内渐缩的外表面；和
对于至少部分这样的层使所述控制器使用所述数据使所述涂布装置垂直于锥体喷涂以填充所述锥体。
可选地，每一条线喷涂的材料与一个或多个相邻线喷涂的材料交错。
可选地，表面扫描仪在构建物体时重复测量物体，并且所述控制装置使用测量结果来调节涂布装置和/或基板和/或喷涂参数，以提高形状参数和完成后的物体之间的匹配精度。
附图说明
下面将参照附图，通过示例的方式对本发明的一些优选实施例进行说明，附图中：
图1为3D冷喷涂打印机的等轴测视图；
图2为由打印机部分成形的三个3D物体的第一层的等轴测视图；
图3为较高阶部分成形物体的等轴测视图；
图4为由打印机部分成形的三个3D物体的几乎完整的两层的等轴测视图；
图5为由打印机分层形成的另一个3D物体的等轴测视图；
图6为用以说明锥形边缘的填充方式的部分成形物体的侧面示意图；
图7为通过喷涂彼此相邻的线建立冷喷涂层的方式的横截面示意图；和
图8为为获得良好的表面迎角通过交错喷涂线，而非相邻喷涂建立冷喷涂层的方式的横截面示意图；
具体实施方式
参照图1，冷喷涂3D打印机1具有涂布装置，该涂布装置包括用于以高速喷涂合适金属粉末喷雾的喷嘴2。已知有许多用于冷喷涂的粉末，本领域技术人员将熟悉这些粉末。将金属粉末喷涂在由包括机械臂3的基板支架保持的基板(未示出)上，以构建3D物体。更具体地，该物体由一个接一个喷涂的一系列平行层形成。
机械臂3优选地使得它可以移动基板，并因此可以使部分成形的3D物体能够沿任何方向进行移动，并移动至任意角度上。在图1的实施例中，喷嘴2是静止的，但在其他实施例中，可以在任何方向或任意角度移动以进行喷涂。
图2示出了在板状基板上的三个部分成形的3D物体的第一层4、5和6。由于喷涂颗粒自喷嘴2呈圆锥形行进，所以喷涂颗粒在中心处比在外边缘更集中且移动速度更快。因此，粉末的沉积不均匀。这使得层4、5和6具有向内渐缩的边缘7、8、9。如果人们想要做一个直边的物体，例如圆柱体，或者其他的轮廓，锥形就不太合适。通过适当地控制喷嘴2和/或机械臂3使基板和在其上部分成形的3D物体相对于喷嘴处于正确的角度和距离来填充锥体。图3显示了层4、5和6层，它们的锥体部分填充了喷涂材料。
图4显示了第一层4、5和6，它们的锥体完全填满，另外在上方还堆叠上了由喷嘴2喷涂形成的第二层10、11和12。在每种情况下，第二层都与第一层平行并且具有尚未填充的锥形边缘。然后以与第一层相同的方式填充锥体。对随后的平行层重复该过程，直到在每种情况下都形成3D圆柱体。
图5显示了一个完整的具有六边形横截面的3D物体13。在这方面，可以适当控制喷嘴2和/或机械臂3/基板，以创建具有直侧面14和突起15的物体。
再次参考图1，打印机包含或连接到计算机化控制器16。这给出了逐渐调节喷嘴2和/或机械臂3/基板之间的距离和角度以便打印3D物体的指导。这可以包括确保喷嘴与其正在作用的表面正交。在这方面，控制器16运行与定义3D物体形状的数据文件(如.STL格式)交互的软件。换句话说，数据为软件提供了一组指令。
数据在一系列切片方面定义3D物体的形状，每个切片对应于前面提到的一个层。当控制喷嘴2和/或机械臂3/基板以横向沉积行程填充锥度时，控制器16根据概念堆叠中下一个切片或横截面的参数计算并确定最佳喷嘴迎角和到锥度的距离。下一切片的基底可用于划定用于填充下面的锥体的概念边界。控制器16还计算喷涂持续时间、粉末进料速率、喷涂速度、粉末/喷涂温度和所用喷涂材料类型方面的必要喷涂参数。
喷嘴2和/或机械臂3/基板的移动可以由控制器直接完成，例如，在控制器和/或喷嘴2和/或机械臂3包含能够在任意三维空间移动基板和/或喷嘴的机械部件的情况下。然而，在其他实施例中，控制器16可导致喷嘴和机械臂3/基板间接移动，例如通过操纵多轴定位装置来实现相同的三维运动。
优选地，对每一层进行填充，以实现与基板平行的平面顶面。然而，这并不是必要的，在某些情况下可以采用其他方法。
在本发明的一些实施例中，可以通过包括用于测量每一层形成时其边缘的装置来提高精确度，例如使用激光线扫描器、立体成像仪或结构光照相机。测量结果实时传递给控制器16，用于计算和调整喷嘴、基板或喷涂参数的运行。
图6示出了填充锥形边缘的优选方式。在这方面，控制器16使喷嘴2在“工具路径”中围绕每个锥形部分的圆周喷涂，以提供必要的填充。随着机械臂3/基板的移动，控制器使得部分成形的3D物体的锥形边缘基本上保持与喷嘴2的主喷涂轴线垂直。角度的垂直特性用17表示。该运动使得喷嘴的名义纵轴18穿过点19，点19为锥体填充完后物体的角。
在本发明的优选形式中，机械臂3/基板扫过喷嘴2由控制器16调节，以沉积交错的喷涂材料线。在某些应用中，这样可以提高沉积率。
图7是如何可选地通过一系列冷喷涂材料线构建层的横截面示意图，其中每条线都是相邻喷涂的。“x”轴表示基板上的线性距离(毫米)，“y”轴表示喷嘴和基板之间的线性高度间距(毫米)。沿着“x”轴的三角形显示出了各个线条的位置，并给出了材料沉积的横截面或分布的指示。较高的光滑曲线代表了在喷涂线条时实际形成的材料累积量。由于这些线是相邻的，它们之间的距离是固定的，所以喷雾打到表面的角度是倾斜的，这样可以使沉积率降到最低。
图8是当相邻喷涂时如何建立冷喷涂材料线的横截面示意图。“x”轴表示基板上的线性距离(毫米)，“y”轴表示距基板的线性高度(毫米)。沿着“x”轴的三角形显示出了各个线条的位置，并给出了材料沉积的横截面或分布的指示。较高的曲线表示喷涂线时形成的材料的累积量。由于线是以交错方式而不是相邻的方式喷涂，所以集成体积以更平坦的方式构建而成。
尽管已经通过示例描述了一些优选实施例，但是应当理解，在不脱离本发明的范围的情况下可以进行修改和改进。

Claims (8)

1.一种形成3D物体的方法，其特征在于，其包括参照定义物体3D形状参数的数据运行控制装置，使所述控制装置：
使用所述数据控制涂布装置和/或基板支架，使喷涂材料先喷在基板上，再喷在部分成形后的物体上，以逐步施加的层构建所述物体，其中至少有部分层具有初始向内渐缩的外表面；以及
对于至少部分这样的层使所述控制装置使用所述数据使所述涂布装置采用喷涂材料填充锥体。
2.根据权利要求1所述的方法，其特征在于，喷涂是包括金属粉末的冷喷涂。
3.根据权利要求1或2所述的方法，其特征在于，填充所述锥体涉及所述控制装置：
根据喷涂特性计算所述锥体的参数；
计算适用于填充所述锥体的所述涂布装置和锥体之间的角度；以及
使所述涂布装置和锥体成所述角度，并使所述涂布装置将喷涂材料喷涂到所述锥体上。
4.根据权利要求1、2或3所述的方法，其特征在于，所述数据在一系列层方面定义所述3D物体，并且所述控制装置使用下一层的预定义参数控制所述涂布装置和所述锥体之间的用于喷涂填充所述锥体的角度。
5.根据前述权利要求中任一项所述的方法，其特征在于，表面扫描仪在构建物体时重复测量物体，并且所述控制装置使用测量结果来调节所述物体(当部分成形时)和所述喷嘴的相对位置、和/或所述喷嘴的喷涂参数，以提高形状参数和完成后的物体之间的匹配精度。
6.一种形成3D物体的方法，其特征在于，包括参照数据运行计算机化控制器，所述数据在概念切片方面定义物体的3D形状参数，使所述控制器：
使用所述数据控制所述涂布装置先于基板上、再于部分成形的物体上在相邻线处喷涂包括金属粉末的材料，以用与所述切片相对应的逐渐施加的层来构建所述物体，其中至少部分层具有初始向内渐缩的外表面；和
对于至少部分这样的层使所述控制器使用所述数据使所述涂布装置垂直于锥体喷涂以填充所述锥体。
7.根据权利要求6所述的方法，其特征在于，每一条线喷涂的材料与一个或多个相邻线喷涂的材料交错。
8.根据权利要求7所述的方法，其特征在于，表面扫描仪在构建物体时重复测量物体，并且所述控制装置使用测量结果来调节涂布装置和/或基板和/或喷涂参数，以提高形状参数和完成后的物体之间的匹配精度。
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