WO2022139736A1 - Additive manufacturing method for metal or ceramic added 3d printing using photopolymers and 3d printer using this method - Google Patents
Additive manufacturing method for metal or ceramic added 3d printing using photopolymers and 3d printer using this method Download PDFInfo
- Publication number
- WO2022139736A1 WO2022139736A1 PCT/TR2021/051220 TR2021051220W WO2022139736A1 WO 2022139736 A1 WO2022139736 A1 WO 2022139736A1 TR 2021051220 W TR2021051220 W TR 2021051220W WO 2022139736 A1 WO2022139736 A1 WO 2022139736A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- printer head
- printer
- composite mixture
- extruder
- paste
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 20
- 239000000919 ceramic Substances 0.000 title claims description 19
- 238000007639 printing Methods 0.000 title claims description 9
- 239000002184 metal Substances 0.000 title claims description 6
- 238000004519 manufacturing process Methods 0.000 title abstract description 13
- 239000000654 additive Substances 0.000 title abstract description 5
- 230000000996 additive effect Effects 0.000 title abstract description 5
- 230000004927 fusion Effects 0.000 claims abstract description 7
- 230000008021 deposition Effects 0.000 claims abstract description 5
- 239000000203 mixture Substances 0.000 claims description 16
- 239000002131 composite material Substances 0.000 claims description 13
- 239000000843 powder Substances 0.000 claims description 12
- 238000002156 mixing Methods 0.000 claims description 10
- 238000010146 3D printing Methods 0.000 claims description 5
- 230000005540 biological transmission Effects 0.000 claims description 5
- 210000000056 organ Anatomy 0.000 claims description 5
- 239000011347 resin Substances 0.000 claims description 5
- 229920005989 resin Polymers 0.000 claims description 5
- 238000000110 selective laser sintering Methods 0.000 abstract description 9
- 239000000463 material Substances 0.000 abstract description 7
- 238000005516 engineering process Methods 0.000 abstract description 6
- 238000002844 melting Methods 0.000 abstract description 5
- 230000008018 melting Effects 0.000 abstract description 5
- 238000010894 electron beam technology Methods 0.000 abstract description 2
- 238000006116 polymerization reaction Methods 0.000 abstract description 2
- 230000007547 defect Effects 0.000 description 2
- 230000001939 inductive effect Effects 0.000 description 2
- 238000000960 laser cooling Methods 0.000 description 2
- 238000004093 laser heating Methods 0.000 description 2
- 239000002905 metal composite material Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
Classifications
-
- 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
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/40—Radiation means
- B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/50—Means for feeding of material, e.g. heads
-
- 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
- B29C64/205—Means for applying layers
- B29C64/209—Heads; Nozzles
-
- 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
- B29C64/307—Handling of material to be used in additive manufacturing
- B29C64/314—Preparation
-
- 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
- B29C64/307—Handling of material to be used in additive manufacturing
- B29C64/321—Feeding
-
- 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
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
-
- 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
- B33Y70/00—Materials specially adapted for additive manufacturing
- B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
- C22C32/0094—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with organic materials as the main non-metallic constituent, e.g. resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/10—Formation of a green body
- B22F10/18—Formation of a green body by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
Definitions
- AM additive Manufacturing
- SLS Selective Laser Sintering
- FDM Fusion Deposition Modeling
- FFF Fusion Filament production
- SLA Stereolithography
- EBM Electron Beam Melting
- DLP Digital Light Polymerization
- Thermal gradients under rapid laser heating and cooling rates within ceramic parts keeps to be an important factor inducing defects such as cracks and distortions. Although preheating the powder beds can help moderating this phenomenon, the high melting points of ceramics place more strain on the manufacturing process. The rough surface quality of ceramic parts after processing, undesirable porosity and large shrinkage also limit their application areas.
- Figure 1 Perspective view of the three dimensional printer.
- Figure 2 Side view of the three dimensional printer.
- a photosensitive resin (Photopolymer resin) is mixed with ceramic powder or metal powder.
- the ceramic or metal powder ratio can be increased to 80-90%, unlike other methods.
- the mixture which is made to the consistency of paste, can be pressed on a flat surface with the help of a spiral using a transmission organ like a hose.
- the infrastructure of the FDM (Fusion deposition modelling) 3D printer can be used.
- the paste-like mixture is connected to the printer head with a feeding hose (10) such as a plastic hose. Normally the FDM 3D printer has a heater.
- the heater used in FDM is deactivated and instead a single screw, push extruder is used.
- a powerful UV source is placed just under the extruder. The extruder spiral presses the mixed paste into the hose, and the paste that comes out of the extruder nozzle hardens as soon as it is exposed to UV light.
- the printer consists of the motors (1) moving on the X, Y and Z axes, the paste mixing unit (2), the spiral spring (5) to press the raw material to the printer head, the printer head (3), the UV source (6) under the printer head screw (4) and the control screen (7).
- the three dimensional printer using Fusion Deposition Modelling has the following in its most basic form
- Printer head (3) which is the nozzle part of the extruder and where the composite mixture is transferred to the printing plate
- Feeding motor (8) that enables the composite mixture to be transmitted to the feeding hose (10),
- UV source (6) which enables the resin (composite mixture) used for the product to harden and is located under the screw of the printer head
- Control screen (7) where all functions of the 3D printing device are controlled.
- the related composite mixture can also be prepared in another device and transferred to the printer head (3) with the help of an extruder.
- the UV source (6) comprises UV lamps radiating in the entire visible region, and the control screen (7) means the computer hardware and screen on which all functions of the 3D printing device are controlled.
Abstract
There are several different types of Additive Manufacturing (AM) depending on the type of material to be produced. The common point of all of these methods is that the object to be produced is drawn in any CAD program and divided into layers to be printed on a 3D printer. The AM method includes various technologies such as Selective Laser Sintering (SLS), Fusion Deposition Modeling (FDM), Fusion Filament production (FFF), Stereolithography (SLA), Electron Beam Melting (EBM) and Digital Light Polymerization (DLP) for the production of complex, high-volume net-shape components.
Description
ADDITIVE MANUFACTURING METHOD FOR METAE OR CERAMIC ADDED 3D PRINTING USING PHOTOPOEYMERS AND 3D PRINTER USING THIS METHOD
Field of Invention
There are several different types of Additive Manufacturing (AM) depending on the type of material to be produced. The common point of all of these methods is that the object to be produced is drawn in any CAD program and divided into layers to be printed on a 3D printer. The AM method includes various technologies such as Selective Laser Sintering (SLS), Fusion Deposition Modeling (FDM), Fusion Filament production (FFF), Stereolithography (SLA), Electron Beam Melting (EBM) and Digital Light Polymerization (DLP) for the production of complex, high- volume net- shape components.
State of the Art of the Invention (Prior Art)
Although there are many technologies in 3D printing of ceramics, the proportion of ceramic powder does not exceed 60% by volume, except for bulk solid-based technologies such as SLS and SLM, which use laser beams that causes residual stresses.
Thermal gradients under rapid laser heating and cooling rates within ceramic parts keeps to be an important factor inducing defects such as cracks and distortions. Although preheating the powder beds can help moderating this phenomenon, the high melting points of ceramics place more strain on the manufacturing process. The rough surface quality of ceramic parts after processing, undesirable porosity and large shrinkage also limit their application areas.
In addition, one of the biggest limitations of SLS today is the lack of materials that can be produced in powder form needed for this printing method, which affects the low variety of materials available.
Brief Description and Aims of the Invention
Although there are many technologies in 3D printing of ceramics, the proportion of ceramic powder does not exceed 60% by volume, except for bulk solid-based technologies such as Selective Laser Sintering (SLS) and Selective Laser Melting (SLM), which use laser beams that causes residual stresses. Thermal gradients under rapid laser heating and cooling rates within ceramic parts keeps to be an important factor inducing defects such as cracks and distortions. Although preheating the powder beds can help moderating this phenomenon, the high melting points of ceramics place more strain on the manufacturing process. The rough surface quality of ceramic parts after processing, undesirable porosity and large shrinkage also limit their application areas. In addition, one of the biggest limitations of SLS today is the lack of materials that can be produced in powder form needed for this printing method, which affects the low variety of materials available.
Both the FDM and SLA techniques are limited to polymeric materials only, whereas the subject matter of the present invention is both a new technique in this field and offers reliable use for metal and ceramic materials. On the other hand, this method is both inexpensive and easy to use.
Definitions of Drawings Explaining the Invention
The figures prepared to better explain the three dimensional printer developed with this invention are explained below.
Figure 1 - Perspective view of the three dimensional printer.
Figure 2 - Side view of the three dimensional printer.
Figure 3 - Side view of the feeding unit
Definition of Elements/Pieces/Parts Composing the Invention
To better explain the three dimensional printer developed with this invention, the parts/pieces/elements in the figures prepared are numbered separately and the explanation of each number is given below.
1. Motor
2. Paste mixing unit
3. Printer head
4. Transmission organ (Extruder screw)
5. Spiral spring
6. UV source
7. Control screen
8. Feeding Motor
9. Feeding System
10. Feeding Hose
Detailed Description of the Invention
This study is briefly a new technique for new 3D additive manufacturing methods for ceramic, metal and composite materials. According to this technique, in the first stage, a photosensitive resin (Photopolymer resin) is mixed with ceramic powder or metal powder. In this method, the ceramic or metal powder ratio can be increased to 80-90%, unlike other methods. The mixture, which is made to the consistency of paste, can be pressed on a flat surface with the help of a spiral using a transmission organ like a hose. In this method, the infrastructure of the FDM (Fusion deposition modelling) 3D printer can be used. At this point, the paste-like mixture is connected to the printer head with a feeding hose (10) such as a plastic hose. Normally the FDM 3D printer has a heater. In this method, the heater used in FDM is deactivated and instead a single screw, push extruder is used. On the other hand, a powerful UV source is placed just under the extruder. The extruder spiral presses the mixed paste into the hose, and the paste that comes out of the extruder nozzle hardens as soon as it is exposed to UV light.
In this study, part of the FDM technique for printing ceramic and metal composites, mixing ceramic or metal powder and photosensitive resin in paste consistency and using UV light is essential and this is a different point from other methods.
This invention covers the design and production of 3D printers for ceramic or metal composite production. The printer consists of the motors (1) moving on the X, Y and Z axes,
the paste mixing unit (2), the spiral spring (5) to press the raw material to the printer head, the printer head (3), the UV source (6) under the printer head screw (4) and the control screen (7).
The three dimensional printer using Fusion Deposition Modelling has the following in its most basic form;
• Motors (1) that move the plate on which the part to be 3D printed along the X, Y, Z axes is placed,
• The paste mixing unit (2), where the composite mixture is prepared,
• Printer head (3), which is the nozzle part of the extruder and where the composite mixture is transferred to the printing plate,
• Feeding hose (10) that transmits the composite mixture taken from the paste mixing unit to the printer head,
• Feeding motor (8) that enables the composite mixture to be transmitted to the feeding hose (10),
• Transmission organ (extruder screw) (4) that provides the transfer of the pastelike mixture to the printer head,
• Spiral spring (5), which ensures that the extruder nozzle (printer head) is pressed onto the product printing platform,
• UV source (6), which enables the resin (composite mixture) used for the product to harden and is located under the screw of the printer head,
• Control screen (7) where all functions of the 3D printing device are controlled.
The related composite mixture can also be prepared in another device and transferred to the printer head (3) with the help of an extruder. The UV source (6) comprises UV lamps radiating in the entire visible region, and the control screen (7) means the computer hardware and screen on which all functions of the 3D printing device are controlled.
Claims
CLAIMS A three dimensional printer using Fusion Deposition Modelling and comprising:
• Motors (1) that move the plate on which the part to be 3D printed along the X, Y, Z axes is placed,
• The paste mixing unit
(2), where the composite mixture is prepared,
• Printer head (3), which is the nozzle part of the extruder and where the composite mixture is transferred to the printing plate,
• Feeding hose (10) that transmits the composite mixture taken from the paste mixing unit to the printer head,
• Control screen (7) where all functions of the 3D printing device are controlled, characterized in that; it further comprises:
• Feeding motor (8) that enables the composite mixture to be transmitted to the feeding hose (10),
• Transmission organ (extruder screw) (4) that provides the transfer of the pastelike composite mixture to the printer head,
• Spiral spring (5), which ensures that the extruder nozzle (printer head) is pressed onto the product printing platform,
• UV source (6), which enables the composite mixture used for the product to harden and is located under the screw of the Printer head. A method of operation of a three dimensional printer according to claim 1, characterized in that it comprises the steps of:
• Mixing the photosensitive photopolymer resin with ceramic powder or metal powder in the paste mixing unit,
• Pressing the mixture, which has been brought to paste consistency in the paste mixing unit, to a flat surface with the help of a spiral spring using the transmission organ,
• Hardening of the paste coming out of the nozzle of the printer head (extruder) by exposing to UV light.
5
3. A three dimensional printer according to claim 1, characterized in that the feeding hose (10) is a plastic hose.
6
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
TR202021198 | 2020-12-22 | ||
TR2020/21198 | 2020-12-22 | ||
TR202104413 | 2021-03-08 | ||
TR2021/004413 | 2021-03-08 |
Publications (1)
Publication Number | Publication Date |
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WO2022139736A1 true WO2022139736A1 (en) | 2022-06-30 |
Family
ID=82160011
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/TR2021/051220 WO2022139736A1 (en) | 2020-12-22 | 2021-11-16 | Additive manufacturing method for metal or ceramic added 3d printing using photopolymers and 3d printer using this method |
Country Status (1)
Country | Link |
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WO (1) | WO2022139736A1 (en) |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20140265034A1 (en) * | 2013-03-12 | 2014-09-18 | Orange Maker LLC | 3d printing using spiral buildup |
CN105618756A (en) * | 2015-08-25 | 2016-06-01 | 国家电网公司 | Device for realizing 3D metal printing by virtue of supporting structure |
KR20180099285A (en) * | 2017-02-28 | 2018-09-05 | 주식회사 그립플레이 | A 3d-printer with improved precision of driving |
CN211071828U (en) * | 2019-11-06 | 2020-07-24 | 北京科技大学 | 3D printing device for laser selective solidified metal |
-
2021
- 2021-11-16 WO PCT/TR2021/051220 patent/WO2022139736A1/en active Application Filing
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20140265034A1 (en) * | 2013-03-12 | 2014-09-18 | Orange Maker LLC | 3d printing using spiral buildup |
CN105618756A (en) * | 2015-08-25 | 2016-06-01 | 国家电网公司 | Device for realizing 3D metal printing by virtue of supporting structure |
KR20180099285A (en) * | 2017-02-28 | 2018-09-05 | 주식회사 그립플레이 | A 3d-printer with improved precision of driving |
CN211071828U (en) * | 2019-11-06 | 2020-07-24 | 北京科技大学 | 3D printing device for laser selective solidified metal |
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