TWI659866B - 立體列印裝置及其列印方法 - Google Patents

立體列印裝置及其列印方法 Download PDF

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TWI659866B
TWI659866B TW106105176A TW106105176A TWI659866B TW I659866 B TWI659866 B TW I659866B TW 106105176 A TW106105176 A TW 106105176A TW 106105176 A TW106105176 A TW 106105176A TW I659866 B TWI659866 B TW I659866B
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coating film
photosensitizer
dimensional
printing device
dimensional printing
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TW106105176A
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TW201831337A (zh
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李衛華
康鴻鵬
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三緯國際立體列印科技股份有限公司
金寶電子工業股份有限公司
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Priority to TW106105176A priority Critical patent/TWI659866B/zh
Priority to ES17169386T priority patent/ES2743510T3/es
Priority to KR1020170056921A priority patent/KR102045213B1/ko
Priority to EP17169386.4A priority patent/EP3363620B1/en
Priority to JP2017094088A priority patent/JP6498233B2/ja
Priority to US15/600,233 priority patent/US10788752B2/en
Publication of TW201831337A publication Critical patent/TW201831337A/zh
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Abstract

一種立體列印裝置，包含一液槽、一移動平台、一光源模組、一控制單元、一感光劑塗佈單元及一曝光顯影單元；液槽用以盛裝一液態成型材，移動平台配置於液槽上；光源模組可移動地配置於液槽上方並提供一光源以照射液態成型材。控制單元耦接於移動平台及光源模組，用以控制移動平台沿著第一方向於液槽中移動，致使一立體物件的至少一切層物件逐層固化於移動平台上；感光劑塗佈單元電連接於控制單元，用以於每一切層物件的外表面形成至少一感光劑塗佈膜；曝光顯影單元電連接於控制單元，用以對感光劑塗佈膜進行曝光而使立體物件具備顏色變化。

Description

立體列印裝置及其列印方法
本創作是關於列印裝置及列印方法，且特別是有關於立體列印裝置及其列印方法。
一般來說，利用逐層建構模型等加成式製造技術(additive manufacturing technology)來建造物理三維(three dimensional；簡稱3D)模型之技術主要是將電腦輔助設計(computer aided design；簡稱CAD)等軟體所建構的3D模型的設計資料轉換為連續堆疊的多個薄橫截面層，再以立體列印裝置依據3D模型的設計資料所建構的空間座標XYZ在基座的上方沿著XY平面移動，從而使建構材料形成正確的橫截面層形狀。之後，藉由列印裝置沿著軸向Z逐層移動，即可使多個橫截面層沿Z軸逐漸堆疊，進而使建構材料在逐層固化的狀態下形成立體物件。
以光固化成型技術來實現立體物件的立體列印系統因具有成型速度快、系統供作穩定及精度高等優點而被廣泛地應用於製作精細零件。前述的立體列印系統透過光源固化建構材料而形成立體物件，列印模組適於浸入盛裝在液槽中的液態成型料材中，而光源模組在XY平面上照射作為建構材料的液態成型材，以使液態成型材被固化，並堆疊在列印模組的一移動平台上。如此，藉由列印模組的移動平台沿著軸向Z逐層移動，即可使液態成型材逐層固化並堆疊成立體物件。
在過去，形成彩色物件的方式可藉由改變液態成型材的顏色來實現；然而在前述製程中，必須多次更換不同顏色的液態成型材，增加製作複雜度。為了簡化製作複雜度，有部分廠商係於立體物件成型過程中或立體物件成型完成後，以一或多色油墨噴塗於立體物件上來改變立體物件的顏色；然仍有著色效果不佳的問題產生。因此，如何能提高立體列印之物件的著色效果，仍是本領域開發人員的主要課題。
依據本發明提供一種立體列印裝置，包含，包含一液槽、一移動平台、一光源模組、一控制單元、一感光劑塗佈單元及一曝光顯影單元；液槽用以盛裝一液態成型材；移動平台配置於該液槽上；光源模組提供一光源以照射液態成型材。控制單元耦接於移動平台及光源模組，用以控制移動平台沿著一第一方向升降，致使一立體物件的至少一切層物件被固化於移動平台上。感光劑塗佈單元電連接於控制單元，用以於每一切層物件的外表面形成至少一感光劑塗佈膜；曝光顯影單元電連接於控制單元，用以對感光劑塗佈膜進行曝光顯影程序，致使立體物件具備色彩。
在本創作的一個實施方式中，曝光顯影單元係對形成於每一切層物件上之感光劑塗佈膜個別進行曝光顯影程序。
在本創作的一個實施方式中，曝光顯影單元係於立體物件成型後，再對形成於切層物件的外表面之感光劑塗佈膜進行曝光顯影程序。
在本創作的一個實施方式中，當立體物件之ㄧ切層物件被固化後，控制單元驅使移動平台沿著第一方向升降，以讓切層物件露出液態成型材。
在本創作的一個實施方式中，立體列印裝置更包含一乾燥單元，電連接於控制單元，用以對感光劑塗佈膜進行乾燥程序。
在本創作的一個實施方式中，感光劑塗佈膜包含一樹脂材料及一感光劑，感光劑均勻地分布於樹脂材料中。
在本創作的一個實施方式中，感光劑塗佈膜包含一樹脂材料及一感光劑，樹脂材料中塗佈於切層材料的外表面，感光劑分佈於樹脂材料上。
本發明另一種立體列印裝置之列印方法，其中立體列印裝置適於列印一彩色立體物件，且立體列印裝置包含盛裝一液態成型材之ㄧ液槽及一移動平台；前述方法包含：配置用以照射液槽之ㄧ光源模組；移動移動平台一預定高度以列印立體物件之至少一切層物件，形成至少一感光劑塗佈膜於切層物件的外表面；曝光感光劑塗佈膜以使完成彩色立體物件的著色；以及組合多層交錯排列之切層物件及感光劑塗佈膜以形成立體物件。
在本創作的一個實施方式中，立體列印裝置之列印方法更包含：再形成感光劑塗佈膜之前，移動移動平台以使切層物件露出液態成型材之外。
在本創作的一個實施方式中，立體列印裝置之列印方法更包含：於曝光顯影感光劑塗佈膜之前，乾燥對感光劑塗佈膜。
在本創作的一個實施方式中，組合多層交錯排列之切層物件及感光劑塗佈膜以形成立體物件係早於對感光劑塗佈膜進行曝光。
請參見圖1，其繪示依照本發明第一實施方式之立體列印裝置之電路方塊圖。立體列印裝置為一種利用光固化成型(Stereo Lithography Apparatus；簡稱SLA)技術的立體列印裝置，其適於從立體模型(未繪示)而製造出一立體物件。在圖1中，立體列印裝置10包含一控制單元110、一移動平台120、一光源模組130、一感光劑塗佈單元140、一乾燥單元150及一曝光單元160。控制單元110可連接至筆記型電腦、平板電腦或桌上型電腦等計算機設備30中具有運算功能的處理器300，處理器300可編輯與處理一立體物件的立體模型並傳送相對應立體模型的複數橫截面資訊至立體列印裝置10的控制單元110；立體列印裝置10適於依據處理器300所傳送的立體列印資訊列印出立體物件。需特別說明的是，前述的立體模型可例如為計算機設備30透過電腦輔助設計或動畫建模軟體建構而成的數位立體圖像檔案，處理器300可將前述的立體模型切割為複數橫截面資訊；處理器300可進一步地由前述的橫截面資訊依序獲取出複數切層物件，立體物件20由前述的切層物件堆疊而成。
請同時參見圖2A；移動平台120沿著第一方向D1可移動地配置於液槽100上，液槽100中盛滿液態成型材102，移動平台120的部分浸入於液態成型材102中。液態成型材102可例如是光敏樹脂，其可接受光源模組130提供之具有特定波段的光線(例如紫外光)照射而固化。
光源模組130可例如是雷射元件、振鏡模組、基於數位光源處理技術的光投影模組及發光二極體燈條中之至少一者；在本實施方式中，光源模組130可移動地位於液槽100的上方，並向下照射液態成型材102，以讓移動平台120之一基座122與液面104之間的液態成型材102因光照而固化形成立體物件20中之一切層物件22。
於完成一切層物件22之後，接著於切層物件22的外表面形成至少一感光劑塗佈膜24。請參見圖2B；控制單元110先使得移動平台120相反於第一方向D1移動，使在前所完成之切層物件22露出液面104。接著，感光劑塗佈單元140可移動地位於液槽100的上方，其包含長條形的一感光劑噴嘴142，以將感光樹脂供給切層物件22，藉以在切層物件22的外表面形成一定膜厚的第一感光劑塗佈膜24。前述的感光樹脂可為均勻混合有樹脂材料(例如明膠)及感光劑(例如為鹵化銀)之感光乳劑；其中，感光劑在接受到特定光源照射且經顯影處理後能顯現特定光色。在某些實施方式中，感光劑塗佈單元140可優先在切層物件22的外表面塗佈一樹脂材料，接著再於樹脂材料的外表面塗佈感光劑來實現；換言之，第一感光劑塗佈膜24可至少由包覆切層物件22之一樹脂材料層及附著於樹脂材料外層之感光劑層所構成。
於切層物件22上形成第一感光劑塗佈膜24之後，可選擇性地利用乾燥單元150以對第一感光劑塗佈膜24進行乾燥處理，如圖2C所示；若立體物件20僅具有單一色彩，則於完成乾燥程序後，控制單元110可沿著第一方向D1移動，使得在前所形成的第一感光劑塗佈膜24的頂面與液面104距離一切層物件22的高度，並再次利用光源模組130以固化液態成型材102而形成另一切層物件22以及其上的第一感光劑塗佈模24(即重複圖2A至圖2C所示步驟)，直至完成立體物件20的列印。對第一感光劑塗佈膜24進行乾燥程序有利於其能緊附於切層物件22，進而避免其在浸入液態成型材102，散逸於液態成型材102中。
另一方面，若立體物件20具有多種色彩，則於完成第一感光劑塗佈膜24的乾燥程序後，再利用另一感光劑塗佈單元140於第一感光劑塗佈膜24之上形成第二感光劑塗佈膜26，如圖2D所示；其中，對第一感光劑塗佈膜24進行乾燥程序還可有效地避免第一感光劑塗佈膜24與第二感光劑塗佈膜26相溶，進而導致立體物件20產生混色或著色效果不佳的問題。
第一感光劑塗佈模24及第二感光劑塗佈膜26可與不同波段的光產生光化學反應，且第一感光劑塗佈膜24及第二感光劑塗佈膜26所使用之光的波段不同於液態成型材102的固化光源的波段。於切層物件22上形成第二感光劑塗佈膜26之後，可選擇性地利用如圖2C所示乾燥單元150以對第二感光劑塗佈膜26進行乾燥處理。當然，於完成感光劑塗佈膜26後，還可使用類似於形成第一感光劑塗佈膜24及第二感光劑塗佈膜26之方法於第二感光劑塗佈膜26之上形成第三感光劑塗佈膜(未圖示出)，來增加立體物件20的色彩多樣性。
可於單一切層材料22在完成第一感光劑塗佈膜24(及第二感光劑塗佈膜26)塗佈後，直接對第一感光劑塗佈膜24(及第二感光劑塗佈膜26)進行如圖2E所示的曝光程序；或者，也讓控制單元110控制移動平台120沿著第一方向D1移動，使得在前所形成的第一感光劑塗佈膜24(或第二感光劑塗佈膜26)的頂面與液面104距離一切層物件的高度，並再次利用光源模組130以固化液態成型材102而形成另一切層物件22以及其上的第一感光劑塗佈模24(及第二感光塗佈膜26)，直至完成立體物件20的列印後再進行如圖2E的曝光程序。最後，再將立體物件20浸入顯影液中以達到顯影著色效果。
在此要特別說明的是，第一感光塗佈膜24(及第二感光劑塗佈膜26)中的感光樹脂除了可以感光劑噴嘴142來供給切層物件22，也可以使用如圖3所示的滾輪來供給切層物件22；滾輪的外表面可先附著有感光樹脂，藉由滾動來讓感光樹脂附著於切層物件22的外表面。之後可再利用如圖2C所示的乾燥單元150以乾燥第一感光佈膜24(及第二感光劑塗佈膜26)。
請參見圖4A-4C，其等分別繪示依照本創作第三實施方式之立體列印方法於中間製程之示意圖。執行立體列印方法之立體列印裝置可例如為圖1所繪示之立體列印裝置10，其可包含一控制單元110、一移動平台120、一光源模組130、一感光劑塗佈單元140、一乾燥單元150及一曝光顯影單元160。移動平台120沿著第一方向D1可移動地配置於液槽100上，液槽100中盛滿液態成型材102；液態成型材102可例如是光敏樹脂，其可接受光源模組130提供之具有特定波段的光線(例如紫外光)照射而固化。
光源模組130可移動地位於液槽100的下方，並向上照射液態成型材102，以讓移動平台120之ㄧ基座122與液槽100的底部之間的液態成型材102因光照而固化形成立體物件20中之ㄧ切層物件22。
請參見圖4B，於完成一切層物件22之後，接著於切層物件22的外表面形成至少一感光劑塗佈膜24。更具體言之，控制單元110會先讓移動平台120沿著第一方向D1上升，以讓在前所完成之切層物件22露出液面104。接著，感光劑塗佈單元140的一感光劑噴嘴142可移動地靠近切層物件22，並將感光樹脂供給切層物件22，藉以在切層物件22的外表面形成一定膜厚的第一感光劑塗佈膜24。
在本實施方式中，感光劑塗佈單元140可優先在切層物件22的外表面塗佈一樹脂材料(例如：明膠)240，接著再於樹脂材料240的外表面塗佈感光劑242來實現；換言之，第一感光劑塗佈膜24可至少由包覆切層物件22之一樹脂材料240及附著於樹脂材料240上之感光劑242所構成。於單一切層材料22完成第一感光劑塗佈膜24塗佈後，直接對第一感光劑塗佈膜24進行如圖4C所示的曝光程序。
之後，藉由控制單元110控制移動平台120的移動，使切層物件22的至少一部份浸入液態成型材102中，並使第一感光劑塗佈膜24的表面與液槽100的底部之間距離恰好為一切層物件22的高度，並再次以光源模組130照射液態成型材102，以形成另一切層物件22，並依序以圖4B及圖4C所示步驟形成第一感光劑塗佈膜24並使第一感光劑塗佈膜24曝光。
依序重複前段所述步驟直至完成立體物件20的列印後，再將立體物件20浸入顯影液中以達到顯影著色效果。雖然本發明已以實施方式揭露如上，然其並非用以限定本發明，任何熟習此技藝者，在不脫離本發明的精神和範圍內，當可作各種的更動與潤飾，因此本發明的保護範圍當視後附的申請專利範圍所界定者為準。
10‧‧‧立體列印裝置
100‧‧‧液槽
102‧‧‧液態成型材
104‧‧‧液面
110‧‧‧控制單元
120‧‧‧移動平台
122‧‧‧基座
130‧‧‧光源模組
140‧‧‧感光劑塗佈單元
142‧‧‧感光劑噴嘴
150‧‧‧乾燥單元
160‧‧‧曝光顯影單元
30‧‧‧計算機設備
300‧‧‧處理器
20‧‧‧立體物體
22‧‧‧切層物件
24‧‧‧第一感光劑塗佈膜
240‧‧‧樹脂材料
242‧‧‧感光劑
26‧‧‧第二感光劑塗佈膜
D1‧‧‧第一方向
圖1繪示依照本發明第一實施方式之立體列印裝置之電路方塊圖；
圖2A-2E繪示依照本發明第一實施方式之立體列印方法於中間製程之示意圖；以及
圖3繪示依照本發明第二實施方式之立體列印方法於中間製程之ㄧ示意圖；
圖4A-4C繪示依照本發明第三實施方式之立體列印方法於中間製程之示意圖。

Claims (12)

  1. 一種立體列印裝置，包含： 一液槽，用以盛裝一液態成型材； 一移動平台，配置於液槽上； 一光源模組，用以提供一光源以照射該液態成型材； 一控制單元，耦接於該移動平台及該光源模組，用以控制該移動平台沿著一第一方向升降，致使一立體物件的至少一切層物件被固化於該移動平台上； 一感光劑塗佈單元，電連接於該控制單元，用以於每一切層物件的外表面形成至少一感光劑塗佈膜；以及 一曝光顯影單元，電連接於該控制單元，用以對該感光劑塗佈膜進行曝光顯影程序，致使該立體物件具備色彩。
  2. 如請求項第1項所述之立體列印裝置， 其中該曝光顯影單元係對形成於每一切層物件上之該感光劑塗佈膜個別進行曝光顯影程序。
  3. 如請求項第1項所述之立體列印裝置， 其中該曝光顯影單元係於該立體物件成型後，再對形成於該等切層物件的外表面之該感光劑塗佈膜進行曝光顯影程序。
  4. 如請求項第1項所述之立體列印裝置，其中當該立體物件之ㄧ切層物件被固化後，該控制單元控制該移動平台沿著該第一方向升降，以讓該切層物件露出該液態成型材。
  5. 如請求項第4項所述之立體列印裝置，更包含一乾燥單元，電連接於該控制單元，用以對該感光劑塗佈膜進行乾燥程序。
  6. 如請求項第1項所述之立體列印裝置，其中該感光劑塗佈膜包含一樹脂材料及一感光劑，該感光劑均勻地分布於該樹脂材料中。
  7. 如請求項第1項所述之立體列印裝置，其中感光劑塗佈膜包含一樹脂材料及一感光劑，該樹脂材料塗佈於該切層材料的外表面，該感光劑分佈於該樹脂材料上。
  8. 如請求項第1項所述之立體列印裝置，其中該感光劑塗佈單元為一噴嘴或一滾輪。
  9. 一種立體列印裝置之列印方法，其中該立體列印裝置適於列印一彩色立體物件，且該立體列印裝置包含盛裝一液態成型材之ㄧ液槽及一移動平台，該立體列印裝置之列印方法包含： 配置用以照射該液槽之ㄧ光源模組； 移動該移動平台一預定高度以列印該立體物件之至少一切層物件， 形成至少一感光劑塗佈膜於該切層物件的外表面； 曝光該感光劑塗佈膜以使完成該立體物件的著色；以及 組合多層交錯排列之該切層物件及該感光劑塗佈膜以形成該立體物件。
  10. 如請求項第9項所述之立體列印裝置之列印方法，更包含： 在形成該感光劑塗佈膜之前，移動該移動平台使該切層物件露出該液態成型材之外。
  11. 如請求項第9項所述之立體列印裝置之列印方法，更包含： 於曝光顯影該感光劑塗佈膜之前，乾燥對該感光劑塗佈膜。
  12. 如請求項第9項所述之立體列印裝置之列印方法，其中組合多層交錯排列之該切層物件及該感光劑塗佈膜以形成該立體物件係早於對該感光劑塗佈膜進行曝光。
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