NL2034928A - Method for manufacturing a helmet by using a multi-degree-of-freedom additive printing - Google Patents
Method for manufacturing a helmet by using a multi-degree-of-freedom additive printing Download PDFInfo
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- NL2034928A NL2034928A NL2034928A NL2034928A NL2034928A NL 2034928 A NL2034928 A NL 2034928A NL 2034928 A NL2034928 A NL 2034928A NL 2034928 A NL2034928 A NL 2034928A NL 2034928 A NL2034928 A NL 2034928A
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- helmet
- printing
- layer
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- filling
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- 238000007639 printing Methods 0.000 title claims abstract description 63
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 21
- 238000000034 method Methods 0.000 title claims abstract description 21
- 239000000654 additive Substances 0.000 title claims abstract description 18
- 230000000996 additive effect Effects 0.000 title claims abstract description 18
- 239000010410 layer Substances 0.000 claims abstract description 52
- 230000011218 segmentation Effects 0.000 claims abstract description 16
- 239000002344 surface layer Substances 0.000 claims abstract description 13
- 229920005989 resin Polymers 0.000 claims abstract description 6
- 239000011347 resin Substances 0.000 claims abstract description 6
- 239000000463 material Substances 0.000 claims description 9
- 238000009941 weaving Methods 0.000 claims description 5
- 229920001169 thermoplastic Polymers 0.000 claims description 4
- 239000004416 thermosoftening plastic Substances 0.000 claims description 4
- 230000008021 deposition Effects 0.000 claims description 2
- 230000000694 effects Effects 0.000 claims description 2
- 239000011159 matrix material Substances 0.000 claims description 2
- 230000002787 reinforcement Effects 0.000 claims description 2
- 239000000805 composite resin Substances 0.000 claims 1
- 230000009977 dual effect Effects 0.000 claims 1
- 239000002131 composite material Substances 0.000 description 5
- 238000010586 diagram Methods 0.000 description 5
- 238000009787 hand lay-up Methods 0.000 description 3
- 238000000465 moulding Methods 0.000 description 3
- 238000004804 winding Methods 0.000 description 3
- 229920000049 Carbon (fiber) Polymers 0.000 description 2
- 239000004917 carbon fiber Substances 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 238000010146 3D printing Methods 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 238000003854 Surface Print Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000005490 dry winding Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 229920006253 high performance fiber Polymers 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
Classifications
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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
- B33Y80/00—Products made by additive manufacturing
-
- 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
-
- 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
- B29C64/118—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
-
- 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
-
- 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
- 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
- B29C64/40—Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
-
- 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
- B33Y50/00—Data acquisition or data processing for 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
- 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
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/10—Geometric CAD
- G06F30/17—Mechanical parametric or variational design
-
- 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
- B29C64/379—Handling of additively manufactured objects, e.g. using robots
-
- 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
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/20—Post-treatment, e.g. curing, coating or polishing
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2113/00—Details relating to the application field
- G06F2113/10—Additive manufacturing, e.g. 3D printing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Abstract
The present invention provides a method for manufacturing a helmet by using a multi-degree-offreedom additive printing. A helmet supporting mold is first printed with water-soluble resin based on an inner surface of a target helmet model; curved equidistant offset layering is performed on the target helmet model from the inner surface to an outer surface according to a feature layer thickness; regional traversal segmentation is performed from inside to outside on a base and protrusions as segmentation targets based on the integrity of curved surface layers, and slice information is stored; conformational processing is performed on all protruding regions after traversal segmentation to reduce wall thickness; filling information of each of series of curved surface layers of a target helmet is obtained based on filling parameter settings; a multi-degree-offreedom printing device performs layer-by-layer filling on the supporting mold along a path to complete the printing of the target helmet.
Description
I
METHOD FOR MANUFACTURING A HELMET BY USING A MULTI-DEGREE-OF-
FREEDOM ADDITIVE PRINTING
The present invention belongs to the field of advanced manufacturing technology, in particular to a method for manufacturing a helmet by using a multi-degree-of-freedom additive printing.
Common forming processes for helmets mainly include hand lay-up molding, three- dimensional weaving forming, and winding forming. The hand lay-up molding is a typical process for helmet production, and is restricted by metal molds that are simple in type and difficult to replace; the 3D weaving forming is mainly for military bulletproof helmets, and penetrates a tying angle interlocking fabric through weaving to improve continuity of the fabric compared with the hand lay-up molding; and the winding process is divided into dry, wet, and semi-dry winding, and mainly involves accurate winding of a prepreg on a rotating mold core at a high speed according to a predetermined path under tension control, curing, and demolding, but such process is not suitable for the manufacturing of concave parts and restricts shapes of formed helmets. Therefore, fixed molds constrain shapes of helmets and, together with performance requirements, limit forming of the helmets.
For helmets with complex curved surfaces, additive manufacturing is currently a new mainstream forming idea. An entire curved surface filling path for a helmet may be obtained by slicing a curved surface of a target helmet model layer by layer and filling each layer, and then a multi-degree-of-freedom robotic arm is introduced to implement multi-degree-of-freedom printing and filling of high-performance fiber reinforced thermoplastic resin based pre-impregnated composite wires according to the path, so as to achieve high-performance forming of a complex curved helmet.
To solve the above problems, the present invention discloses a method for manufacturing a helmet by using a multi-degree-of-freedom additive printing, which aims to relieve multi- directional constraints of conventional helmet forming processes on shapes and performances of helmets based on a complex curved surface layering method, and ultimately achieves high-quality forming of complex curved surfaces.
A method for manufacturing a helmet by using a multi-degree-of-freedom additive printing includes the following steps:
Step 1: extracting shape features of a target helmet model, including feature information of inner and outer surfaces, edge lines and points;
Step 2: setting a feature layer thickness tO and a wall thickness coefficient k, selecting the inner surface of the helmet model, calling a numerical control program, performing equidistant offset layering on the target helmet model from the inner surface to the outer surface by a value of tO to obtain a set of series of curved surface layers, and recording information of each layer in the thickness direction of the model,
Step 3: segmenting the model based on the integrity of each curved surface layer and the segmentation principle of "a base layer + a protrusion layer", traversing protrusions to further refine the segmentation, and finally implementing regional segmentation on the overall model;
Step 4: performing filling conformation on the protrusion layer to reduce the wall thickness by T=k*t0, so as to obtain a filling thickness and slice information of each regional protrusion, where T represents a reduced wall thickness of the helmet;
Step 5: selecting the outer surface, calling the numerical control program, and generating slice information of model wall thickness surface offset layers in combination with the wall thickness value;
Step 6: setting a nozzle diameter, a filling angle, and a filling spacing, and selecting a filling method;
Step 7: selecting the bottom edge line of the model, clicking a starting point, setting a model base filling starting point, and performing layer-by-layer path planning according to the filling principle of "sequential filling of the base layer, followed by a sequential filling of the protrusion layer, followed by a sequential filling of the outer wall" and the parameter settings in step 6) until overall printing path information of the target helmet is obtained; and
Step 8: performing, using a multi-degree-of-freedom printing device, layer-by-layer filling and printing on a target helmet supporting mold according to the printing path information until the target helmet is completed.
Further, the supporting mold needs to be designed according to the inner surface of the target helmet model, and the helmet supporting mold is printed with a soluble resin material based on
Fused Deposition Modeling (FDM) technology, where the material may be a water-soluble resin 3D printing consumable such as PVA, eSoluble, or AquaSys 120;
Further, the target helmet printing material is a common thermoplastic wire, which may be
PLA, ABS, or nylon; or a fiber reinforced resin based pre-impregnated composite wire with the thermoplastic wire as a matrix, which may be a short/continuous carbon fiber reinforced composite wire or a short/continuous glass fiber reinforced composite wire;
Further, the helmet supporting mold is formed in the following two manners: (i). the multi-
degree-of-freedom printing device is equipped with double printing heads, with one for conventional printing of the supporting mold, and the other for curved surface printing of a helmet body; and (ii). the supporting mold is printed by a separate FDM printing device and then mounted on a printing table of the multi-degree-of-freedom printing device;
Further, the printing device 1s a 6-axis robotic arm printer, and pose states of the printing heads always satisfy that a nozzle centerline is perpendicular to a path direction;
Further, for information of each curved surface layer obtained by slicing the curved surface of the target helmet model, parameters of each layer of filling path may be set separately, so that materials of all layers are staggered to achieve a weaving reinforcement effect;
Further, after the printing of the target helmet is completed, the target helmet together with the internal helmet mold is removed from a printing platform base and stays in a room temperature sink until the supporting mold dissolves, to obtain a final target helmet product.
Further, each layer is filled separately by means of one of straight filling, zigzag filling, or hollow square filling.
Beneficial effects of the present invention are as follows: 1. The present invention provides a method for manufacturing a helmet by using a multi- degree-of-freedom additive printing for complex curved surface parts: first, a helmet supporting mold is printed with water-soluble resin on an inner surface of a target helmet model; then, curved equidistant offset layering is performed on the target helmet model from the inner surface to an outer surface according to a feature layer thickness; next, regional traversal segmentation is performed from inside to outside on a base and protrusions as segmentation targets based on the integrity of curved surface layers, and slice information is stored; 2. Conformational processing is performed on all protruding regions after traversal segmentation to reduce the wall thickness; filling information of each of series of curved surface layers of a target helmet is obtained based on filling parameter settings; a multi-degree-of-freedom printing device performs layer-by-layer filling on the supporting mold along a path to complete the printing of the target helmet; finally, the helmet and the supporting mold are put into the sink together, the mold dissolves, and the final target helmet product is obtained. 3. The method provides a new solution for additive manufacturing of helmet products with complex curved structures.
FIG. 1 is a schematic diagram of a target helmet, a supporting mold, and a printing platform according to the present invention.
FIG. 2 is a schematic diagram of a step of equidistant offset layering according to the present invention.
FIG. 3 is a schematic diagram of a step of traversal region segmentation according to the present invention.
FIG. 4 is a schematic diagram of a step of protrusion filling conformation according to the present invention.
FIG. 5 is a schematic diagram of regional printing process steps according to the present invention (where) - sequential filling of a base; sequential filling of protrusion layers; &- sequential filling of outer wall).
Reference numerals 1 - target helmet model; 2 - helmet supporting mold; 3 - printing platform base.
The present invention will be further illustrated below with reference to the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are merely used to explain the present invention and not to limit the scope of the present invention. It should be noted that the terms "front", "back", "left", "right", "up", and "down" used in the following description refer to directions in the drawings, and the terms "inside" and "outside" refer to directions towards or away from a geometric center of a specific component respectively.
A method for manufacturing a helmet by using a multi-degree-of-freedom additive printing according to this embodiment includes the following steps: 1) A target helmet model with a thickness of 4.8 mm is determined. Shape features of the target helmet model, including feature information of inner and outer surfaces, edge lines and points, are extracted. A helmet supporting mold is built according to the inner surface of the helmet model, and a water-soluble supporting mold is printed with an eSoluble material and mounted on a 6-axis printing platform base; 2) A feature layer thickness (tO) of 0.6 mm and a wall thickness coefficient of (k) 3 are set, path editing is performed on the inner surface of the helmet model based on an NX software, such as for example the NC module version 12.0 from Siemens, equidistant offset layering is implemented on the target helmet model from the inner surface to the outer surface by 0.6 mm to obtain a set of series of curved surface layers, in particular a total of 8 layers, and information of each layer in the thickness direction of the model is recorded, 3) The model is segmented based on the integrity of each curved surface layer and the segmentation principle of "a base layer + a protrusion layer", protrusions are traversed to further refine the segmentation, and finally regional segmentation is implemented on the overall model to obtain a set of base layer regions and protrusion layer regions; 4) Filling conformation is performed on the protrusion layer regions to reduce the wall thickness (T) by 1.8 mm=3*0.6 mm, so as to obtain a filling thickness and slice information of each regional protrusion (5 layers); 5 5) Path editing is performed on the outer surface based on the NX software NC module, and slice information of 3 model wall thickness surface offset layers is generated in combination with the wall thickness value; 6) 3K continuous carbon fiber reinforced PLA composite pre-impregnated wires with a diameter of 0.8 mm are used as a helmet printing material, a nozzle diameter of 1.0 mm, a filling angle of 45°, a filling spacing of 0.8 mm, and a "zigzag filling" method are set, and a relative filling transformation angle of each curved surface layer is 90° (namely, the filling angle is 45° for the first layer, -45° for the second layer, 45° for the third layer, etc.); 7) The bottom edge line of the model is selected, a starting point is determined, a model base filling starting point is set, layer-by-layer path planning is performed according to the filling principle of "sequential filling of the base layer followed by sequential filling of the protrusion layer followed by sequential filling of the outer wall" and the parameter settings in step 6) until overall printing path code of a target helmet is obtained, pose states of printing heads are converted to always satisfy that a nozzle centerline is perpendicular to a path direction, and a final printing code of a 6-axis printing device is generated, 8) The multi-degree-of-freedom printing device performs layer-by-layer filling and printing on the target helmet supporting mold according to the printing code until the target helmet is completed, 9) The target helmet and the supporting mold are removed from the printing platform base and placed in a sink until the mold hydrolyzes, the target helmet is taken out, and the printing is completed.
The technical means disclosed in the solution of the present invention are not limited to the technical means disclosed in the foregoing embodiments, but also include technical solutions formed by any combination of the above technical features.
Claims (8)
Applications Claiming Priority (1)
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CN202210684578.8A CN114986872B (en) | 2022-06-17 | 2022-06-17 | Multi-degree-of-freedom additive manufacturing printing method for helmet |
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NL2034928A true NL2034928A (en) | 2023-07-28 |
NL2034928B1 NL2034928B1 (en) | 2024-01-18 |
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CN (1) | CN114986872B (en) |
NL (1) | NL2034928B1 (en) |
WO (1) | WO2023240747A1 (en) |
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CN116373305B (en) * | 2023-01-05 | 2024-04-02 | 南京航空航天大学 | Space curved surface printing path planning method based on equidistant discrete |
CN116352018B (en) * | 2023-02-09 | 2024-02-02 | 南京航空航天大学 | Gradient self-adaptive printing shape control method for multi-material composite sand mold |
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WO2023240747A1 (en) | 2023-12-21 |
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