CN110997281A - 3d打印方法 - Google Patents

3d打印方法 Download PDF

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CN110997281A
CN110997281A CN201880050049.4A CN201880050049A CN110997281A CN 110997281 A CN110997281 A CN 110997281A CN 201880050049 A CN201880050049 A CN 201880050049A CN 110997281 A CN110997281 A CN 110997281A
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史蒂文·卡米莱里
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Yifuren Technology Intellectual Property Private Ltd
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Abstract

一种3D打印物品的方法，包括以下步骤：a)在基板上以三维方式打印物品的部件；b)相对于保持该部件或基板的保持装置对部件进行重新定向；以及c)在第一次提及的部件上以三维方式打印物品的另一部件。

Description

3D打印方法
技术领域
本发明涉及一种通过3D打印生产物品的方法。在优选形式中，本发明涉及在3D打印中使支撑材料的需求最小化。
背景技术
通常，3D打印机通过将打印材料以渐增的方式添加到基板上来成形物品。这种打印机具有能够指导材料放置位置的运动控制系统。控制系统可以连接到打印头(例如，分配喷涂材料的部分)或基板(例如，成形时保持部分成形件)，或打印头和基板两者。一般来说，当物品成形时，存在各种力作用于物品上(例如重力和惯性力等)。因此，通常需要将打印头和基板牢固地固定，并且将部分成形件牢固地固定在基板上。
基板和打印头的配置方式可以限制打印材料的添加位置。例如，打印头通常不能通过将打印材料遍布到基板来在部分成形件上施加打印材料。相反，打印材料只能在物品成形时施加于物品开放或暴露的部分。这会限制能够由给定打印机打印的几何图形的可行范围。
在打印过程中，通常还需要在基板上添加支撑材料以保持打印材料，例如，要生成的物品具有在重力作用下容易变形的明显悬臂部的情况。通常，打印作业结束后，从成品中机械移除支撑材料。移除支撑材料的麻烦，加上打印和废弃其的成本，引发出了一系列旨在最小化支撑材料使用的设计理念。在某些情况下，支撑材料是可溶性物质。
本发明的优选实施例的目的是至少在某种程度上解决上述一个或多个限制。然而，应当理解，本发明的目的本身只是提供一种有用的选择。因此，适用于任何优选实施例的任何目的或优点不应被视为对更广泛地表达的权利要求范围的限制。
发明内容
根据本发明的一个方面，提供了一种3D打印物品的方法，包括以下步骤：
a)在基板上以三维方式打印物品的部件；
b)相对于保持所述部件或所述基板的保持装置对所述部件进行重新定向；以及
c)在第一次提及的部件上以三维方式打印物品的另一部件。
可选地，步骤b)包括将第一次提及的部件从所述基板上脱离，重新定向该部件，然后将该部件与所述基板重新结合，或将该部件与所述保持装置或另一基板结合。
可选地，所述重新定向包括45°-180°的变化。
可选地，所述方法在物品成形时未为物品提供任何支撑的情况下进行，以上第一次和/或第二次提及的基板除外。
可选地，所述物品由从喷头喷射的打印材料成形。
可选地，所述打印材料是冷喷涂的。
可选地，所述喷头和/或至少第一次提及的基板在计算机式控制器的影响下移动，以便在成形所述物品时将所述打印材料作为冷喷涂剂进行定向放置，所述移动由记录的物品的几何参数来引导。
可选地，所述几何参数在概念上将要成形的所述物品分成不同的部件，其中至少一个部件被指定为在打印后相对于保持所述部件或所述第一次提及的基板的装置来重新定向。
可选地，方法是：
a)步骤b)包括将所述第一次提及的部件与所述基板脱离，重新定位所述部件，然后将所述部件与所述基板重新结合或与所述保持装置或另一基板结合；
b)所述重新定向包括45°-180°的变化；
c)所述方法在物品成形时未为物品提供任何支撑的情况下进行，基板除外；
d)所述物品由从喷头冷喷的打印材料成形；
e)所述喷头和/或所述基板或多个基板在计算机式控制器的影响下移动，以便于在成形所述物品时对所述打印材料进行定向放置，所述移动由记录的物品的几何参数来引导；以及
f)所述几何参数在概念上将要形成的所述物品划分为不同的部件，其中至少一个部件被指定为在打印后重新定向。
可选地，将第一次提及的部件从所述基板上脱离是通过对夹具中的基板进行弯曲或冲击加载并使基板沿着与所述部件的界面断裂来实现。
可选地，一个或两个基板与所述物品结合。
可选地，所述打印材料包括以下中一个或多个：
铁合金(如钢)；
粉末有色合金；以及
熔融塑料丝。
附图说明
现在将通过示例并参考其附图来描述本发明的一些优选实施例：
图1为3D打印机的等轴侧视图；
图2为已被3D打印到基板上的物品的侧视图和等轴侧三维视图；
图3示意性地示出了根据本发明实施例的3D打印方法中的六个步骤；以及
图4为成品的等轴侧视图，成品是图3方法的任选产品。
具体实施方式
参考图1，3D打印机的实施例包括手柄1，手柄1包含机械臂2，手柄可以通过机械臂2进行移动。打印机还具有冷喷头3。手柄1保持基板并将其暴露于从喷头3喷射出的打印材料以在基板上成形3D物品。当由打印材料的渐增层6a-e成形时，带有3D物品5的基板4如图2所示。机械臂2在物品成形时会调整位置和方向，以便在物品成形时以正确的角度将打印材料施加于基板的适当部分或施加至部分形成的物品。
如图所示，基板往往会阻止打印头在部分成形的物品上工作，即那些直接靠着基板保持的面。此外，在没有额外支撑的情况下，在与基板相距太远的地方施加喷涂材料会使材料在硬化时容易因重力或其他力而变形。这可以通过在不连续的部分中生成物品来解决。当打印了一部分时，将其从基板上移除，重新定向，与基板重新结合，然后在前面提及的部分上递增地成形另一部分以完成物品。然后将成品从基板上移除。在已完成的前面的部分上进行成型与将两个现成的部分融合在一起是有区别的。
参考图3，在步骤“A”中，夹具7保持空白基板8。然后喷嘴9可控地指向基板8并开始成形目标三维物品的部件10。部件10的完成阶段在步骤“B”中示意。如步骤“C”所示，然后将部件10从基板上移除，如步骤“D”所示，将隔套13安装到夹具上，将部件倒置地附接到隔套上，并继续喷射以成形物品的相对面15，如步骤“E”所示，从而得到完成的物品18，其在没有支撑材料的情况下从两面喷涂，如“F”所示。然后将物品18从隔套中松开。最终生产的物品以三维的方式示出在图4中。
手柄1的移动(以及因此基板的移动)和/或喷头3的移动由计算机式控制器(未示出)来控制。控制器利用要生成物品的几何参数进行编程，并使打印材料从喷头喷出，以正确的角度、速度和温度与基板或部分成形的物品接触，以获得最佳结果。几何参数在概念上将物品分成不连续的部分，并且每一部分可以以平面或非平面终止。举例来说，这些面可以是垂直的，但是对于其他物品，它们可以是水平的，或者介于水平和垂直之间的某处。优选地，在成品中，这些面彼此相对。
虽然图3示出了成品18的两个不连续部分的成形，但在其他实施例中，可以有任意多个部分，每一部分在形状上相同、相似或明显不同。
本发明的一些实施例的有益效果是，可以分阶段容易地生成物品，而无需或大幅减少对支持材料的需求。缺少支撑材料(即在基板上方)也意味着能够在例如打印后生成空腔等事件之后无需移除支撑物的情形下来生产物品。
如上所述，并参考图3，物品的前半部分在制造时可以从基板上脱离，重新定向，然后与夹具7或基板8重新结合。脱离可以通过对夹具中的基板进行弯曲或冲击加载并使其沿着与部件的界面断裂来实现。或者，基板可以包含在物品中。重新夹紧可以通过结合可逆夹紧特征和在喷涂部件上的定位表面来实现，如平面区域，凸耳或螺栓面。这些特征可以通过任何常规或方便的机械加工夹具来实现，如螺栓、指形夹具、肘节夹具或通电夹具和固定装置。浮雕可以融入基板表面。
打印材料如上所述为喷雾。可用于这种类型的材料种类示例为有色金属粉末合金，如铝7075或锰青铜，或粉末钢，如316不锈钢。一种特别优选的材料是Valimet 6061，它在500℃的温度和700m/s的速度下用作冷喷涂剂。在本发明的其他实施例中，打印材料可以用作熔融塑料丝，例如用于熔融沉积熔合(FDM，Fused Deposition Melding)。在这种情况下，印刷材料可以是ABS聚合物。
在冷喷涂沉积的情况下，已经发现一旦部件10重新定向，如果新出现的沉积表面已经经过加工和抛光，最好是镜面抛光，并且温度尽可能升高，通常为100℃左右，则后续喷涂材料可以达到最佳结合。如果采取这些步骤，则重新定向/已经沉积的材料和新沉积的材料之间的结合界面往往会具有比其他情形更高的拉伸强度，通常接近材料本身的拉伸强度。但是，此步骤不是必需的。可采用其他“表面预处理”，如在聚合物3D打印过程(如FDM)中进行表面预热。
上述说明和附图说明了用于保持“翻转”部件的夹紧特征。在某些情况下，需要在“翻转”的部件上添加牺牲性的可移除打印材料(如凸块)，以简化翻转后夹紧部件的过程。以这种方式的打印部件可以在夹紧装置的复杂性与打印部件的复杂性之间权衡或平衡。在3D打印的情况下，总生产量可能是一件，通常希望减小化夹紧装置的复杂性。
在本发明的一些实施例中，当部件翻转时，可以改变喷涂材料。例如，打印部件的一部分，翻转并重新安装部件，将喷涂材料更换为具有所需不同属性的材料，然后继续打印。散热器就是这种技术的一个应用。在这方面，人们发现铝具有良好的散热性能，而铜具有良好的体积性能。可以使用上述技术通过翻转和材料变化来制造具有该两种性能的混合散热器。
虽然已经通过示例描述了本发明的一些优选形式，但应当理解，可以在不脱离以下权利要求的情况下进行修改和改进。

Claims (12)

1.一种3D打印物品的方法，包括以下步骤：
a)在基板上以三维方式打印物品的部件；
b)相对于保持所述部件或所述基板的保持装置来对所述部件进行重新定向；以及
c)在第一次提及的部件上以三维方式打印所述物品的另一部件。
2.根据权利要求1所述的方法，其中，步骤b)包括将第一次提及的部件从所述基板上脱离，重新定向该部件，然后将该部件与所述基板重新结合，或将该部件与所述固定装置或另一基板结合。
3.根据权利要求2所述的方法，其中，所述重新定向包括45°-180°的变化。
4.根据权利要求1、2或3所述的方法，所述方法在物品成形时未为物品提供任何支撑的情况下进行，权利要求1的所述基板和/或权利要求2所述的另一基板除外。
5.根据上述任一权利要求所述的方法，其中，所述物品由从喷头喷射出的打印材料成形。
6.根据权利要求5所述的方法，其中，所述打印材料是冷喷涂的。
7.根据权利要求1至4中任一项所述的方法，其中，所述打印是通过喷头进行的，并且其中所述喷头和/或至少权利要求1中所述的基板在计算机式控制器的影响下进行移动，以便在成形所述物品时将所述打印材料作为冷喷涂剂进行定向放置，所述移动由记录的物品几何参数来引导。
8.根据权利要求7所述的方法，其中，所述几何参数在概念上将要成形的所述物品分成不同的部件，其中至少一个部件被指定为在打印该部件后相对于保持所述第一次提及的部件或基板的装置来重新定向。
9.根据权利要求1所述的方法，其中：
a)步骤b)包括将第一次提及的部件与所述基板脱离，重新定位所述部件，然后将该部件与所述基板重新结合或与所述保持装置或另一基板结合；
b)所述重新定向包括45°-180°的变化；
c)所述方法在成形物品时未为物品提供任何支撑的情况下进行，除了所述基板或多个基板以外；
d)所述物品由从喷头冷喷的打印材料来成形；
e)所述喷头和/或所述基板或多个基板在计算机式控制器的影响下移动，以便在成形所述物品时对所述打印材料进行定向放置，所述移动由记录的物品的几何参数来引导；以及
f)所述几何参数在概念上将要成形的所述物品划分为不同的部件，其中至少一个部件被指定为在被打印后重新定向。
10.根据权利要求9所述的方法，其中，将第一次提及的部件从所述基板上脱离是通过对夹具中的基板进行弯曲或冲击加载并使基板沿着与所述部件的界面断裂来实现。
11.根据权利要求9所述的方法，其中，一个或两个基板与所述物品结合。
12.根据权利要求9、10或11所述的方法，其中，所述打印材料包括以下的一个或更多个：
铁合金；
粉末有色合金；以及
熔融塑料丝。
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