CN110394980A - 立体打印系统 - Google Patents

立体打印系统 Download PDF

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Publication number
CN110394980A
CN110394980A CN201810372783.4A CN201810372783A CN110394980A CN 110394980 A CN110394980 A CN 110394980A CN 201810372783 A CN201810372783 A CN 201810372783A CN 110394980 A CN110394980 A CN 110394980A
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light
dimensional printing
light source
printing system
light emitting
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康鸿鹏
丁明雄
郭宗桦
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Kinpo Electronics Inc
XYZ Printing Inc
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Kinpo Electronics Inc
XYZ Printing Inc
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Priority to CN201810372783.4A priority Critical patent/CN110394980A/zh
Priority to US16/027,551 priority patent/US10850448B2/en
Priority to JP2018128012A priority patent/JP6797155B2/ja
Priority to EP18182447.5A priority patent/EP3560712B1/en
Priority to ES18182447T priority patent/ES2829571T3/es
Publication of CN110394980A publication Critical patent/CN110394980A/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/277—Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
    • B29C64/129—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
    • B29C64/129—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
    • B29C64/135—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/255—Enclosures for the building material, e.g. powder containers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/277—Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
    • B29C64/282—Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED] of the same type, e.g. using different energy levels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • 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
    • 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
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
    • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
    • G03F7/70—Microphotolithographic exposure; Apparatus therefor
    • G03F7/70416—2.5D lithography

Abstract

本发明有关于一种立体打印系统，包含一液槽、一移动平台、一光源模块及一控制模块，液槽用以盛装一液态成型材，移动平台配置于液槽上，并可移动地设置于液槽内；光源模块配置于液槽下方，并提供一光源以照射液态成型材，光源模块包含多个发光二极管；控制模块耦接于光源模块，并驱动光源模块产生一聚焦平面位于移动平台及液槽之间且距离液槽底部一特定位置的光，以便将聚焦平面的液态成型材固化成为立体物件的一切层物件；其中，控制模块依据前述的多个发光二极管中之一者的亮度作为调整其他发光二极管亮度的根据，进而让单一(扫描)操作下成型的该液态成型材具有近似固化硬度。

Description

立体打印系统
技术领域
本发明是关于立体打印系统，且特别是有关于用于提供平行光照射液态成型材来让立体物件具有近似固化硬度的立体打印系统。
背景技术
一般来说，利用逐层建构模型等加成式制造技术(additive manufacturingtechnology)来建造物理三维(three dimensional；简称3D)模型的技术主要是将电脑辅助设计(computer aided design；简称CAD)等软件所建构的3D模型的设计数据转换为连续堆叠的多个薄横截面层，再以立体打印系统依据3D模型的设计数据所建构的空间坐标XYZ在基座的上方沿着XY平面移动，从而使建构材料形成正确的横截面层形状。之后，藉由打印系统沿着轴向Z逐层移动，即可使多个横截面层沿Z轴逐渐堆叠，进而使建构材料在逐层固化的状态下形成立体物件。
以光固化成型技术来实现立体物件的立体打印系统因具有成型速度快、系统供作稳定及精度高等优点而被广泛地应用于制作精细零件。图1绘示依照现有立体打印系统的架构图。立体打印系统1通过光固化建构材料(以下称“建构材料”)而形成立体物件12，打印模块14适于浸入盛装在液槽16中的液态成型料材18中，而光源模块20在XY平面上照射作为建构材料的液态成型材18，以使液态成型材18被固化，并堆叠在打印模块14的一移动平台140上。如此，藉由打印模块14的移动平台140沿着轴向Z逐层移动，即可使液态成型材18逐层固化并堆叠成立体物件12。
然而，从图1的XY平面观之，光源模块20提供的光线呈扇型分布，这会造成液态成型材料的固化硬度内外不同。更具体言之，如图2所示，光线到成型面S的长度不同；举例来说，光线射出点(即O点)到成型面右侧A点的距离会大于光线射出点至成型面中间B点的距离，这造成在焦平面不同处的液态成型材所接收到的光亮度不同，因而造成在单一(扫描)操作下成型的液态成型材料具有不同的固化硬度。
发明内容
依据本发明提供一种立体打印系统，包含一液槽、一移动平台、一光源模块及一控制模块，液槽用以盛装一液态成型材，移动平台配置于液槽上，并可移动地设置于液槽内；光源模块配置于液槽下方，并提供一光源以照射液态成型材，光源模块包含多个发光二极管；控制模块耦接于光源模块，并驱动光源模块产生一聚焦平面位于移动平台及液槽之间且距离液槽底部一特定位置的光，以便将聚焦平面的液态成型材固化成为立体物件的一切层物件；其中，该控制模块依据这些发光二极管中之一者的亮度作为调整其他发光二极管亮度的根据，进而让单一(扫描)操作下成型的该液态成型材具有近似固化硬度。
附图说明
本文的附图仅仅用于说明性目的。附图并不旨在限制本公开的范围。
图1绘示依照现有立体打印系统的架构图；
图2绘示依照现有立体打印系统的光学路径图；
图3绘示根据本发明一实施方式的立体打印系统的架构图；
图4绘示根据本发明一实施方式的光源模块的局部放大图；以及
图5绘示根据本发明一实施方式的控制模块的局部电路方块图。
其中，附图标记：
1、10…立体打印系统
100、16…液槽
101…内表面
102、18…液态成型材
110…控制模块
112…位移暂存器
114…记忆单元
116…控制单元
120…移动平台
130、20…光源模块
132…发光二极管
1320…出光面
134…光整型件
136…驱动单元
14…打印模块
140…移动平台
50…切层物件
d…特定距离
S…聚焦平面
具体实施方式
以下结合附图和具体实施例对本发明进行详细描述，但不作为对本发明的限定。
图3绘示根据本发明一实施方式的立体打印系统的架构图。在图3中，立体打印系统为为一种利用光固化成型(Stereo Lithography Apparatus；简称SLA)技术的立体打印系统，其适于从立体模型(未绘示)而制造出一立体物件。在图1中，立体打印系统10包含一控制模块110、一移动平台120及一光源模块130。控制模块110可连接至笔记型电脑、平板电脑或桌上型电脑等计算机设备(图中未视出)，计算机设备可编辑与处理一立体物件的立体模型并传送相对应立体模型的多个横截面信息至立体打印系统10的控制模块110。立体打印系统10适于依据计算机设备所传送的立体打印信息打印出立体物件。需特别说明的是，前述的立体模型可例如为计算机设备通过电脑辅助设计或动画建模软件建构而成的数字立体图像文件，计算机设备可进一步将前述的立体模型切割为多个横截面信息，并由前述的横截面信息依序获取出多个切层物件50，立体物件由前述的切层物件50堆叠而成。
移动平台120沿着Z轴方向可移动地配置于液槽100上，液槽100中盛满液态成型材102，移动平台120可接受控制模块110的控制而移出或移入液态成型材102中。液态成型材102可例如是光敏树脂，其可接受光源模块130提供的具有特定波段的光线(例如紫外光)照射而固化。
光源模块130用以提供能固化液态成型材102的光线；光源模块130提供的光线可穿透液槽100而照射位于移动平台120及液槽100底部的一内表面101之间的液态成型材102，以便将液态成型材102固化并堆叠于移动平台120上。更具体言之，光源模块130产生的光可控制成在液槽100内且离开内表面101特定距离d的一聚焦平面S上聚焦于液态成型材102以便固化液态成型材102，藉以有效地避免液态成型材102内外硬度不同的问题。
光源模块130耦接于控制模块110，接受控制模块110送出的信号而产生能够聚焦在聚焦平面S的光。在本发明中，光源模块130可包含多个发光二极管132、多个光整型件134及驱动单元136，如图4所示；每个发光二极管132用以产生光型大致呈扇形的发散光，光整型件134个别地配置在发光二极管132及聚焦平面S之间，用以将发光二极管132产生的发散光进行整形并聚焦于聚焦平面S。
在此要特别说明的是，当光源模块130提供的光为面型光时，于单一次(扫描)操作中，立体打印系统10可成型一面切层物件50，故光源模块130无需额外增设移动机构件使其移动以便于对不同方向进行扫描；然而，当光源模块130提供的光为线性光时，于单一次(扫描)操作中，只有面型切层物件50的其中一列或其中一行得以固化成型，故光源模块130需额外增设移动机构件(图中未视)来让其得以沿着X轴或Y轴移动以便成型面状的切层物件50。
光整型件134的数量相同于发光二极管132的数量，且每个发光二极管132及其对应的光整型件134可配合提供用以固化前述的横截面信息中单一像素所对应的切层物件50的光。
光整型件134可为会聚透镜或柱状透镜。如图4所示，光源模块130可经适当地设计而让光整型件134的中心至发光二极管132的出光面1320之间的距离L1相同于光整型件134的中心至聚焦平面S之间的距离L2；藉此可有效地缩减光源模块130的高度，进而可降低立体打印系统10的运费。
驱动单元136接收来自于控制模块110的控制信号，并将其转换成为发光二极管132能够解读的数据，并可依据计算机设备所传送的立体打印信息在不同次扫描操作中选择所点亮的发光二极管132的数量。
进一步地，归因制程公差，光源模块130中的每个发光二极管132产生的光的亮度(以下称亮度)不尽相同，这使得投射到聚焦平面的光的均匀度不佳，进而影响切层物件50的成型品质。更具体言之，在亮度较强的位置，液态成型材102能够在预定时间内顺利固化成型；相对地，在亮度较弱的位置，液态成型材102将无法在预定时间内顺利固化成型或固化硬度不如其它亮度较强处的问题产生；申言之，发光二极管132的亮度不均会使得切层物件50出现固化硬度不同的问题。
为了避免发光二极管132亮度不均匀影响立体物件的成形品质，可以图5所示的控制模块110的局部电路来让光源模块130中每个发光二极管132产生的亮度均匀一致。图5绘示根据本发明一实施方式的控制模块的局部电路方块图。为了方便说明，图5中同时绘示出发光二极管132及驱动单元136；控制模块110包含一位移暂存器112、记忆单元114及一控制单元116，其中位移暂存器112为串行的位移暂存器，藉以避免使用过多的输入端口。记忆单元114可为电子抹除式可复写唯读记忆体(Electrically-Erasable Programmable Read-Only Memory；缩写EEPROM)，其内部可预先储存有对应每一个发光二极管132的最大亮度信息。
控制模块110的能够接收来自于计算机设备提供的立体打印信息中的发光序列信号、锁存信号及时序信号，以及来自于记忆单元114的最大发光亮度的数据并输出至少一控制信号予驱动单元136；驱动单元136用于依据控制信号产生一驱动信号以驱动发光二极管。
发光序列信号可由数据输入端口Data In进入控制模块110，锁存信号可由数据锁存端口Data latch进入控制模块110，时序信号则由时序端口CLK进入控制模块110。发光序列信号可以串行(serial)的方式输入至控制模块110。位移暂存器112可另外自记忆单元114接收对应每一个发光二极管的最大亮度信息。
归因于发光序列信号以串行的方式输入至控制模块110，故需要经过N个时脉的时间，对应于单一(扫描)操作的发光序列信号才会完整被一个位移暂存器112所接收；因此，可利用锁存信号于时序信号经过预定周期后对发光序列信号进行锁存以产生对应于单一(扫描)操作所需的发光二极管的切换信号。控制单元116接着可根据切换信号及来自于记忆单元114的发光二极管的最大亮度信息来产生对应于不同(扫描)操作下，每个发光二极管所需的控制信号予驱动单元136。
在此要特别说明的是，控制单元116提供的控制信号可为脉冲调变信号；因此，控制单元116可以藉由改变控制信号的工作周期(duty cycle)来对具有不同最大亮度的发光二极管提供不同的导通时间，进而使得每一像素所对应的液态成型材102能接收到相同的能量以便于具有近似固化硬度。举例来说，可以最大亮度为最低的发光二极管具有最大工作周期(例如100％)，并降低其它发光二极管的工作周期来达让液态成型材102具有近似固化硬度。
此外，控制单元116也可以藉由调整控制信号改变传递至具有不同最大亮度的发光二极管的能量(例如:电流)，来改变发光二极管的亮度，进而使得每一像素所对应的液态成型材102能接收到近似的能量以便于具有近似硬度的固化。举例来说，可以最大亮度为最低的发光二极管具有最大的导通电流，并降低其它发光二极管的导通电流来达让液态成型材102具有近似固化硬度。
当然，本发明还可有其它多种实施例，在不背离本发明精神及其实质的情况下，熟悉本领域的技术人员当可根据本发明做出各种相应的改变和变形，但这些相应的改变和变形都应属于本发明所附的权利要求的保护范围。

Claims (10)

1.一种立体打印系统，其特征在于，包含：
一液槽，用以盛装一液态成型材；
一移动平台，配置于该液槽上，并可移动地设置于该液槽内；
一光源模块，配置于该液槽下方，并提供一光源以照射该液态成型材，该光源模块包含多个发光二极管；
一控制模块，耦接于该光源模块，并驱动该光源模块产生一聚焦平面位于该移动平台及该液槽之间，并距离该液槽底部一特定位置的光，以便将聚焦平面的该液态成型材固化成为立体物件的一切层物件，
其中，该控制模块依据这些发光二极管中之一者的亮度作为调整其他发光二极管亮度的根据，进而让单一操作下成型的该液态成型材具有近似固化硬度。
2.如权利要求1所述的立体打印系统，其特征在于，该光源模块更包含多个光整型件，这些光整型件配置于该焦平面及这些发光二极管之间，以将各该发光二极管发出的光线对焦于该焦平面。
3.如权利要求2所述的立体打印系统，其特征在于，这些光整型件的数量相同于这些发光二极管的数量，且各该光整型件对应配置在这些发光二极管中之一者与该焦平面之间。
4.如权利要求2所述的立体打印系统，其特征在于，各该光整形件为会聚透镜或柱状透镜。
5.如权利要求1所述的立体打印系统，其特征在于，该控制模块包含：
一记忆单元，供储存各该发光二极管的该最大亮度信息；
一位移暂存器，接收一发光序列信号；以及
一控制单元，耦接于该记忆单元及该位移暂存器，
其中，该控制单元依据该发光序列信号及各该发光二极管的该最大亮度信息以产生该控制信号。
6.如权利要求5所述的立体打印系统，其特征在于，该位移暂存器更接收一锁存信号及一时序信号，并依据该发光序列信号、该锁存信号及该时序信号产生对应于各该发光二极管于单一操作所需的一切换信号，该控制单元依据该切换信号及各该发光二极管的该最大亮度信息产生该控制信号。
7.如权利要求5所述的立体打印系统，其特征在于，该控制单元调整各该发光二极管所需的该控制信号的工作周期来让单一操作时固化的该液态成型材具有近似硬度。
8.如权利要求5所述的立体打印系统，其特征在于，该控制单元调整传递给各该发光二极管的该控制信号来改变各该发光二极管的导通时间，进而让单一操作时固化的该液态成型材具有近似硬度。
9.如权利要求5所述的立体打印系统，其特征在于，该记忆单元为电子抹除式可复写唯读记忆体。
10.如权利要求1所述的立体打印系统，其特征在于，该控制模块更耦接于该移动平台，以控制该移动平台远离该光源模块，使一立体物件的至少一切层物件被固化于该移动平台上。
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