WO2022252689A1 - Manufacturing method based on 3d printing and injection molding - Google Patents

Manufacturing method based on 3d printing and injection molding Download PDF

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Publication number
WO2022252689A1
WO2022252689A1 PCT/CN2022/076285 CN2022076285W WO2022252689A1 WO 2022252689 A1 WO2022252689 A1 WO 2022252689A1 CN 2022076285 W CN2022076285 W CN 2022076285W WO 2022252689 A1 WO2022252689 A1 WO 2022252689A1
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printing
printed
injection
manufacturing
injection molding
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PCT/CN2022/076285
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French (fr)
Chinese (zh)
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周应国
杨金强
孙弘龙
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江苏科技大学
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Publication of WO2022252689A1 publication Critical patent/WO2022252689A1/en

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C69/00Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
    • B29C69/02Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore of moulding techniques only
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/25Process efficiency

Definitions

  • the invention relates to a molding method, in particular to a manufacturing method based on 3D printing and injection molding.
  • 3D printing technology is also known as additive manufacturing technology, referred to as 3D printing. It is based on the idea of discrete/accumulation, and uses computer software to process the CAD 3D model of the product in layers along a certain direction to obtain the processing information of the cross-sectional profile of each layer. , through the layered processing of the 3D printer, layer by layer superimposition, quickly and accurately transform the design concept into a prototype with certain functions or directly manufacture parts. Due to the advantages of quickly obtaining design product prototypes and breaking through difficult-to-process parts in traditional manufacturing, 3D printing technology has increasingly become the focus of attention in many industries, and its applications are also expanding.
  • the purpose of the present invention is to provide a manufacturing method based on 3D printing and injection molding, which can obtain one or more aspects of mechanical properties, conductivity properties or other performance properties that exceed the combined parts of ordinary injection products, and manufacture
  • the process has good repeatability and strong implementability, and is suitable for mass production.
  • a manufacturing method based on 3D printing and injection molding described in the present invention comprises the following steps:
  • thermoplastic polymer raw material into the injection mold, and after cooling, the 3D printed part and the polymer raw material injected after injection form a uniform composite part
  • the invention specially designs the processed 3D printed parts as in-mold inserts of the injection products, and finally forms a product processing method in which the 3D printed parts and the injection melt are integrated.
  • the use target of the part includes the improvement of mechanical properties, electrical properties, etc.; analyze the structure of the injection part to be processed, determine its characteristics and use targets, and then determine the 3D printing production target.
  • the embedding position, size and shape characteristics of the parts are used to carry out the structural design of the 3D printed parts.
  • the structural design of the 3D printed part includes its own structural reinforcement part, in-mold placement part and melt flow control part; wherein, the self-structural reinforcement part mainly ensures the strength of the printed part itself.
  • the self-reinforcing part guarantees The mold cavity does not deform when subjected to a pressure of 0 to 50 MPa.
  • the placement part in the mold is mainly for easy placement when placed in the mold to ensure that its position is fixed when the mold is opened and closed. It is 0.5% to 2 larger than the size of the corresponding position of the mold cavity.
  • the melt flow control part is the functional part of the 3D printing part, which is mainly consistent with the flow direction of the melt during the injection process.
  • the melt flow control part is consistent with the flow direction of the melt in the mold Parallel to each other, thus showing an effect similar to a slender flow channel.
  • the size of the placement part is larger than the size of the corresponding position of the mold cavity to ensure that the 3D printed part is placed in the mold and can be placed in the mold under a slight force. If the size is too small, the fixation will not be firm, and if the size is too large, it will be difficult to install.
  • the design principle of the melt flow control part is: through the restricted flow of the melt in the specified direction, the flow induction effect is improved, and then the mechanical properties of the filled melt are improved.
  • the overall performance of the final product can be improved by improving the interfacial bonding between the post-filled melt and the pre-placed insert.
  • the melt flow control part of the 3D printed part is a slender flow channel, or a micro-groove is provided on the inner wall surface of the slender flow channel; the usual practice of such micro-grooves is to design and print directly on the 3D printed part, But this will add trouble to the corresponding printing control.
  • the micro-grooves are obtained by modifying the original code during the printing process and obtaining more random stop points.
  • the preheating temperature of the 3D printed part is between 5 and 20 degrees lower than its heat distortion temperature, and the temperature difference between the preheating temperature and the injection mold is between 0 and 80 degrees.
  • the temperature of the injection mold may be constant, or a process of variable mold temperature may be adopted.
  • the preheating temperature ensures that the material can be slightly deformed when it is placed, which is convenient for placement. At the same time, the temperature difference between the preheating temperature and the plastic melt after filling is as small as possible to ensure that the difference in shrinkage between the two is the smallest. However, preheating The temperature should not be too high. When it exceeds or approaches the thermal deformation temperature, the strength of the printed part to withstand the injection will be affected, and deformation will occur during injection, which will affect the appearance and performance of the final product.
  • step (4) special post-processing is carried out on the obtained composite part to avoid warping of the product and eliminate its internal stress.
  • the post-processing includes placing the workpiece in a jig matching the shape of the workpiece, and keeping it at a temperature 10-20 degrees lower than the melting point for 5-20 minutes.
  • the melt flow regulation part of the 3D printed part is provided with elongated channel micro-grooves.
  • the interface properties of dissimilar materials need to be considered, and corresponding means can be used to improve the interface bonding effect between dissimilar materials.
  • the 3D printing method of the present invention that can be used for injection molding inserts, in order to improve the melting point between 3D printed parts and post-injection During the printing process, there are many random stop points, and the stop time is between 1 and 1000ms. Each stop point forms a micro-gully on the printed piece.
  • the present invention also provides a method for directly modifying the printing code.
  • Mainly include the following steps: (1) determine the interval distance of the stay points; (2) determine the number of interval points according to each print segment; (3) determine the position of each interval point; (4) modify the code of the print segment and insert N stays Click the code, and modify the amount of printing materials synchronously.
  • the resulting article of the invention has an insert manufactured using 3D printing.
  • 3D printing and injection molding can use the same material or different materials.
  • the process used for 3D printing products can be one or a combination of FDM, SLS, POLYJET, MJF, SLA and other processes.
  • the present invention also provides a specific application of the above-mentioned combined product of 3D printing and injection molding, which has advantages in one or more aspects of mechanical properties, electrical conductivity, and thermal conductivity.
  • the invention uses the characteristics of the 3D printed parts to flexibly design the structure of the part, and designs a structure that facilitates the filling of the melt in the cavity and maintains the orientation, so as to realize the performance control of the polymer injection molding product in part or all spaces .
  • the method of using the stop point will add a small amount of raw materials to the material at the position of the stop point, thereby increasing the interface bonding between the filling melt and the printed part,
  • injection molding has high production efficiency and can process products with complex shapes, it can be applied not only to thermoplastics, but also to thermosetting plastics. Therefore, products processed by this process are widely used, and it is currently one of the industrial production methods for plastic products. a common process. However, injection molding is also often faced with the need for local reinforcement of parts, improvement of mechanical properties or conductivity.
  • 3D printing and injection molding has the following technical difficulties: when the 3D printed parts are put into the injection mold and then injected and filled, they will also face a series of problems, and the 3D printed parts cannot be placed in the injection mold well. Internal; when the pressure of injection filling is high, the 3D printed part may not be able to bear it and cause severe deformation; the interface between the 3D printed part and the post-filled melt is poor; Parts are prone to warping, etc.
  • the present invention provides a method for combined manufacturing of 3D printing and injection molding, which comprehensively solves the problems faced when using this method for combined manufacturing. , the design of related devices and molds, etc., to obtain one or more aspects of mechanical properties, conductivity or other performance properties that exceed the combined parts of ordinary injection products.
  • This process has good repeatability and strong implementability, and is suitable for batch production. chemical production.
  • the method of combining 3D printing and injection molding of the present invention has the following beneficial effects:
  • stop points in the printing process may not be reflected in its structural design. These stop points are formed by directly modifying the code later, and the positions are randomly distributed, so that there will be no hindrance to the flow of the melt on a macro level effect, and will not affect the structure of the print itself.
  • Fig. 1 is technological process schematic diagram of the present invention
  • Fig. 2 is a schematic diagram of the process route of the present invention.
  • Fig. 3 is a design drawing of the 3D printing part of the present invention.
  • Fig. 4 is an outline view of the 3D printed part obtained in Example 1 of the present invention, that is, a 3D printed insert in the form of micro-grooves.
  • Fig. 5 is an outline view of the 3D printed part obtained in Example 2 of the present invention, that is, the 3D printed insert without grooves.
  • Fig. 6 is an outline view of the part of Comparative Example 1, which has a 3D printed insert in the form of a macroscopic ravine.
  • Fig. 7 is the outline drawing of the workpiece of Comparative Example 2, a grid-like printed part.
  • Figure 8 is the product obtained after the 3D printed part is filled with PP material;
  • Figure A is the product of Comparative Example 1, which has serious warping without preheating and post-treatment;
  • Figure B is the product of Comparative Example 1 Part, the part has been preheated, but not post-treated, and the warpage is slightly better;
  • Figure C is the part of Example 1, and the warpage is completely eliminated.
  • Fig. 9 is a scanning electron micrograph of the cross-sectional structure of the product of the embodiment of the present invention.
  • Fig. 10 is a scanning electron micrograph of a cross-sectional structure of a comparative product.
  • the 3D printing and injection molding combined manufacturing method described in the present invention mainly includes three key technical details of preliminary preparation, molding process, and post-processing.
  • an ordinary injection machine and 3D printer are required; the injection raw material used is thermoplastic resin, and the 3D printing raw material is determined according to its corresponding process, and the raw and auxiliary materials used are all commercially available.
  • FIG. 1, 2 is technological process and route schematic diagram of the present invention, and main realization step of the present invention comprises the following steps:
  • thermoplastic polymer raw material into the injection mold, and after cooling, the 3D printed part and the polymer raw material injected after injection form a uniform combined part
  • PC/ABS is used as the raw material for 3D printing
  • PP is used as the raw material for injection.
  • the tensile strength of PP is 27.5MPA
  • the Young's modulus is 1099MPa
  • the tensile strength of PC/ABS printed parts is 45.7MPa.
  • the modulus is 1975MPa.
  • the 3D printing process used is FDM. Its implementation process is as follows:
  • the structure of the 3D printed part mainly includes three parts, the bottom part is fixed to the mold, Its width is controlled at 10.1mm, the end reinforcement part, the width is 10mm, and the elongated flow channel part, its cross-sectional part accounts for 40% of the cross-sectional volume of the entire injection part (including the bottom fixed part); the printed part is shown in Figure 4 Among them, the left part of the part is the self-reinforcing part, the lower part of the part is the placement part in the mold, and the upper right part of the part is the melt flow control part, and there are fine grooves in the melt flow control part.
  • the software automatically generates the 3D printing source code.
  • the 3D printing source code is modified, and the stop point is enhanced during the printing process.
  • the specific method for determining the stop point is: Performance goals, determine to enhance a stop point within the interval distance of 5 to 10 mm; 2) In the printing code, determine the position of each interval point and its code; 3) Modify the code of the printing section, insert the code of the stop point, and modify it synchronously The amount of printing material used.
  • G1 X63.132 Y11.081 E13.77165//Continue printing to (63.132, 11.081)E increment indicates the amount of printing material
  • the PP raw material is filled into the injection mold, and after cooling, the 3D printed part and the polymer raw material injected after injection form a uniform combined part, and its appearance is shown in Figure 7;
  • the resulting combined parts are subjected to warpage and post-processing of stress distribution, that is, the parts are placed in a fixture that is compatible with its shape, and kept at a temperature of 10 to 30 degrees below the melting point for 5 to 20 minutes.
  • PC/ABS is used as the raw material for 3D printing
  • PP is used as the raw material for injection.
  • the tensile strength of PP is 27.5MPA
  • the Young's modulus is 1099MPa
  • the tensile strength of PC/ABS printed parts is 45.7MPa.
  • the modulus is 1975MPa.
  • the 3D printing process used is FDM. Its implementation process is as follows:
  • the structure of the 3D printed part mainly includes three parts, the bottom part is fixed to the mold , its width is controlled at 10.1mm, the end reinforcement part, the width is 10mm, and the slender flow channel part, its cross-sectional part accounts for 45% of the entire cross-sectional volume of the injection part (including the bottom fixed part); the printed part is shown in Fig.
  • the left part of the part is the self-reinforcing part
  • the lower part of the part is the placement part in the mold
  • the upper right part of the part is the melt flow control part, that is, the slender runner part.
  • the basic structure of the part is similar to that in Figure 4, but lacks micro-grooves, and the arms of the melt flow regulation part are relatively smooth.
  • the software automatically generates the 3D printing source code, and directly prints out the part according to the code, as shown in Figure 4.
  • the PP raw material is filled into the injection mold, and after cooling, the 3D printed part and the polymer raw material injected after injection form a uniform combined part, and its appearance is also shown in Figure 7;
  • the resulting combined parts are subjected to warpage and post-processing of stress distribution, that is, the parts are placed in a fixture that adapts to its shape, and kept at a temperature of 10 to 30 degrees below the melting point for 5 to 20 minutes According to the different performance characteristics of the printed parts, products with excellent mechanical properties, or special conductivity properties, or special control effects can be obtained.
  • Comparative Example 1 is mainly compared with the code retention effect in Example 1.
  • the main method is to stay the code in Example 1 and design some macroscopic grooves directly in the printed part, as shown in Figure 6, but the existence of these grooves will destroy the flow of the melt instead, thus showing the improvement in the performance of the part Insufficient on.
  • Comparative Example 2 is mainly compared with Example 2.
  • the 3D printed part is designed in a grid shape. This structure is easy to design and print. The appearance of the printed part is shown in Figure 7. After the same process as in Example 2 Finally, the tensile strength of the obtained product is only 29.1MPa, and the Young's modulus is 1489MPa.
  • PA is used as the raw material for 3D printing
  • PP is used as the raw material for injection.
  • the tensile strength of PP is 27.5MPa
  • the Young's modulus is 1099MPa
  • the tensile strength of PA printed parts is 46.2MPa
  • the Young's modulus is 1591 MPa.
  • the 3D printing process used is powder laser sintering SLS. Its implementation process is consistent with embodiment 2.
  • the tensile performance test of the prepared product shows that the tensile strength of the product obtained after combining 3D printing and injection molding is as high as 40.2MPa, and the Young's modulus is 1489MPa, which obviously exceeds the mechanical properties of pure PP. It also exceeds the theoretical value calculated by the two-phase law model (the tensile strength converted by the two-phase law model should be 35.91MPa, and the tensile modulus should be 1320MPa).
  • Example 4 The raw materials used in this comparative example are the same as in Example 4, and the structural design of the 3D printed part is consistent with that of Comparative Example 2.
  • the tensile strength of the obtained product is only 36.2MPa, Young’s modulus
  • the weight is 1336MPa, thus shows that embodiment 4 is more obvious to the promoting effect of mechanical property.

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Abstract

Disclosed are a manufacturing method based on 3D printing and injection molding, comprising: performing structural design on a 3D printed part, and completing the processing of the 3D printed part; preheating the 3D printed part and then putting same into a corresponding position of an injection mold; injecting a thermoplastic polymer raw material into the injection mold, cooling and then shaping the material, so that the 3D printed part and the injected polymer raw material form a uniform combined part; and post-processing the obtained combined part for warping and stress distribution to obtain a product. According to the present invention, a combined part of which one or more aspects of mechanical properties, conduction properties or other service properties are superior to those of a common injection product can be obtained, and the manufacturing process is good in repeatability, high in practicability and suitable for batch production.

Description

一种基于3D打印和注射成型的制造方法A manufacturing method based on 3D printing and injection molding 技术领域technical field
本发明涉及一种成型方法,特别是涉及一种基于3D打印和注射成型的制造方法。The invention relates to a molding method, in particular to a manufacturing method based on 3D printing and injection molding.
背景技术Background technique
三维打印技术又被称作增材制造技术,简称3D打印,它基于离散/堆积的思想,通过计算机软件将制品的CAD三维模型沿某一方向分层切片处理,得到每层截面轮廓的加工信息,经三维打印机分层加工,层层叠加,快速、精确地将设计概念转变为具有一定功能的原型或直接制造零件。由于可以快速得到设计产品原型、突破传统制造中难加工部件等优点,三维打印技术越来越成为诸多行业领域关注的焦点,其应用也在不断拓展。3D printing technology is also known as additive manufacturing technology, referred to as 3D printing. It is based on the idea of discrete/accumulation, and uses computer software to process the CAD 3D model of the product in layers along a certain direction to obtain the processing information of the cross-sectional profile of each layer. , through the layered processing of the 3D printer, layer by layer superimposition, quickly and accurately transform the design concept into a prototype with certain functions or directly manufacture parts. Due to the advantages of quickly obtaining design product prototypes and breaking through difficult-to-process parts in traditional manufacturing, 3D printing technology has increasingly become the focus of attention in many industries, and its applications are also expanding.
然而,目前3D打印制件的生产效率往往较低,特别是,用3D打印来加工类似注射成型制件时,仍然不具备大规模生产的可能性;同时,3D打印制件的力学性能稳定性相对较低,这给其应用于加工大型零部件增加了一些限制。However, the current production efficiency of 3D printed parts is often low, especially when 3D printing is used to process similar injection molded parts, it still does not have the possibility of mass production; at the same time, the stability of mechanical properties of 3D printed parts Relatively low, which adds some limitations to its application in processing large parts.
发明内容Contents of the invention
发明目的:本发明的目的是提供一种基于3D打印和注射成型的制造方法,能够获得力学性能、传导性能或其它使用性能的一个方面或多个方面超过普通注射制品的组合制件,且制造工艺的重复性好、可实施性强,适合于批量化生产。Purpose of the invention: The purpose of the present invention is to provide a manufacturing method based on 3D printing and injection molding, which can obtain one or more aspects of mechanical properties, conductivity properties or other performance properties that exceed the combined parts of ordinary injection products, and manufacture The process has good repeatability and strong implementability, and is suitable for mass production.
技术方案:本发明所述的一种基于3D打印和注射成型的制造方法,包括以下步骤:Technical solution: A manufacturing method based on 3D printing and injection molding described in the present invention comprises the following steps:
(1)对3D打印制件进行结构设计,并完成3D打印制件的加工;(1) Design the structure of the 3D printed parts and complete the processing of the 3D printed parts;
(2)将3D打印制件预热后放入注射模具相应位置内;(2) Preheat the 3D printed part and put it into the corresponding position of the injection mold;
(3)将热塑性聚合物原料充入注射模具内,经过冷却后,3D打印制件与后注射充入的聚合物原料形成均一的组合制件;(3) Fill the thermoplastic polymer raw material into the injection mold, and after cooling, the 3D printed part and the polymer raw material injected after injection form a uniform composite part;
(4)将所得的组合制件进行翘曲及应力分布的后处理,即得。(4) After the warpage and stress distribution are performed on the obtained combined parts, it is obtained.
本发明根据待加工注射制品的特点与应用目的而特别设计加工出的3D打印制件作为注射制品的模内嵌件并最终形成3D打印制件与注射熔体浑然一体的制品加工方法。According to the characteristics and application purposes of the injection products to be processed, the invention specially designs the processed 3D printed parts as in-mold inserts of the injection products, and finally forms a product processing method in which the 3D printed parts and the injection melt are integrated.
其中,上述步骤(1)中,制件的使用目标包括力学性能、电学性能等的提升等;根据欲加工的注射制件的结构进行分析,确定其特点及使用目标,并进而确定3D打印制件的嵌入位置、尺寸和形状特征,开展3D打印制件的结构设计。Among them, in the above step (1), the use target of the part includes the improvement of mechanical properties, electrical properties, etc.; analyze the structure of the injection part to be processed, determine its characteristics and use targets, and then determine the 3D printing production target. The embedding position, size and shape characteristics of the parts are used to carry out the structural design of the 3D printed parts.
进一步地,3D打印制件的结构设计包括自身结构增强部分、模内安放部分和熔体流动调控部分;其中,自身结构增强部分主要保证打印件自身的强度,作为优选,自身增强部分保证在注射模腔内承受0~50MPa压力时不发生变形,模内安放部分主要是为了放置模具内时能够便于安放,保证模具开合时其位置固定,比模具型腔相应位置的尺寸大0.5%~2%之间,熔体流动调控部分是3D打印制件的功能部分,主要是与熔体在注射过程 中的流动方向保持一致,作为优选,熔体流动调控部分与熔体在模具内的流动方向相互平行,从而表现出一种类似细长流道的效果。Further, the structural design of the 3D printed part includes its own structural reinforcement part, in-mold placement part and melt flow control part; wherein, the self-structural reinforcement part mainly ensures the strength of the printed part itself. As a preference, the self-reinforcing part guarantees The mold cavity does not deform when subjected to a pressure of 0 to 50 MPa. The placement part in the mold is mainly for easy placement when placed in the mold to ensure that its position is fixed when the mold is opened and closed. It is 0.5% to 2 larger than the size of the corresponding position of the mold cavity. %, the melt flow control part is the functional part of the 3D printing part, which is mainly consistent with the flow direction of the melt during the injection process. As a preference, the melt flow control part is consistent with the flow direction of the melt in the mold Parallel to each other, thus showing an effect similar to a slender flow channel.
其中,安放部分的尺寸大于模具型腔对应位置尺寸是为了保证3D打印件放置于模具内的固定,同时在略受力时即可以放于模内。尺寸过小则固定不牢靠,尺寸过大则不便于安放。熔体流动调控部分的设计原理在于:通过熔体在所指定方向上的受限流动,提高了流动诱导作用,进而对充入熔体的力学性能有提升效果。另外,通过提高后充入熔体与提前安放的嵌件之间的界面结合作用来提升最终产品的综合性能。Among them, the size of the placement part is larger than the size of the corresponding position of the mold cavity to ensure that the 3D printed part is placed in the mold and can be placed in the mold under a slight force. If the size is too small, the fixation will not be firm, and if the size is too large, it will be difficult to install. The design principle of the melt flow control part is: through the restricted flow of the melt in the specified direction, the flow induction effect is improved, and then the mechanical properties of the filled melt are improved. In addition, the overall performance of the final product can be improved by improving the interfacial bonding between the post-filled melt and the pre-placed insert.
优选地,3D打印件的熔体流动调控部分为细长流道,或在细长流道内壁表面设有微沟壑形式;这种微沟壑通常的做法是直接在3D打印件上设计并打印,但这会给相应的打印控制增添了麻烦。本申请中的作为一个改进方法,其微沟壑则是通过在打印过程中修改原始代码并获得较多位置随机的停留点而得到的。Preferably, the melt flow control part of the 3D printed part is a slender flow channel, or a micro-groove is provided on the inner wall surface of the slender flow channel; the usual practice of such micro-grooves is to design and print directly on the 3D printed part, But this will add trouble to the corresponding printing control. As an improved method in this application, the micro-grooves are obtained by modifying the original code during the printing process and obtaining more random stop points.
上述步骤(2)中,3D打印制件预热温度低于其热变形温度5~20度之间,并且预热温度和注射模具的温度差值在0度~80度之间。其中,注射模具的温度可以是恒定不变的,也可以采用变模温工艺。In the above step (2), the preheating temperature of the 3D printed part is between 5 and 20 degrees lower than its heat distortion temperature, and the temperature difference between the preheating temperature and the injection mold is between 0 and 80 degrees. Wherein, the temperature of the injection mold may be constant, or a process of variable mold temperature may be adopted.
预热温度保证了材料在安放时能够少量变形,利于安放,同时,预热温度和后充入塑料熔体之间的温度差尽量小,保证两者的收缩率差值最小,不过,预热温度也不能过大,超过或临近热变形温度时,打印件承受注射的力量受到影响,注射时发生变形,影响最终制品的外观及性能。The preheating temperature ensures that the material can be slightly deformed when it is placed, which is convenient for placement. At the same time, the temperature difference between the preheating temperature and the plastic melt after filling is as small as possible to ensure that the difference in shrinkage between the two is the smallest. However, preheating The temperature should not be too high. When it exceeds or approaches the thermal deformation temperature, the strength of the printed part to withstand the injection will be affected, and deformation will occur during injection, which will affect the appearance and performance of the final product.
上述步骤(4)中,对所得的组合制件进行特殊后处理,以避免产品的翘曲,消除其内应力。具体的,后处理包括将制件放置于与所述制件形状相匹配的夹具中,并在低于熔点温度10~20度范围内保持5-20分钟。In the above step (4), special post-processing is carried out on the obtained composite part to avoid warping of the product and eliminate its internal stress. Specifically, the post-processing includes placing the workpiece in a jig matching the shape of the workpiece, and keeping it at a temperature 10-20 degrees lower than the melting point for 5-20 minutes.
作为优选,3D打印件的熔体流动调控部分设有细长流道微沟壑。Preferably, the melt flow regulation part of the 3D printed part is provided with elongated channel micro-grooves.
进一步地,需要考虑异种材料的界面性能,可以采用相应手段提升异种材料之间的界面结合效果,本发明的可用于注射成型嵌件的3D打印方法,为了提高3D打印件与后注射进入的熔体之间的结合力,在打印过程中设置有较多的位置随机的停留点,其停留时间在1~1000ms之间,每一停留点在打印件上就形成微沟壑。Furthermore, the interface properties of dissimilar materials need to be considered, and corresponding means can be used to improve the interface bonding effect between dissimilar materials. The 3D printing method of the present invention that can be used for injection molding inserts, in order to improve the melting point between 3D printed parts and post-injection During the printing process, there are many random stop points, and the stop time is between 1 and 1000ms. Each stop point forms a micro-gully on the printed piece.
为了能够在打印过程中增加停留点,本发明还提供了一种打印代码的直接修改方法。主要包括以下步骤:(1)确定停留点间隔距离;(2)根据每一个打印段确定间隔点数量;(3)确定每一个间隔点位置;(4)修改打印段的代码,插入N个停留点代码,并同步修改打印材料的用量。In order to increase the stop points in the printing process, the present invention also provides a method for directly modifying the printing code. Mainly include the following steps: (1) determine the interval distance of the stay points; (2) determine the number of interval points according to each print segment; (3) determine the position of each interval point; (4) modify the code of the print segment and insert N stays Click the code, and modify the amount of printing materials synchronously.
比如,以停留时间以200ms为例,在打印过程中有如下代码:For example, taking the dwell time as 200ms as an example, there is the following code in the printing process:
……...
G1 X35.783 Y11.081 E13.44863//从(***,***)打印到(35.783,11.081);E表示打 印丝材的总量(下同);G1 X35.783 Y11.081 E13.44863//print from (***,***) to (35.783,11.081); E represents the total amount of printing filament (the same below);
G1 X63.132 Y11.081 E13.77165    //继续打印到(63.132,11.081)E的增量表示打印材料的用量;G1 X63.132 Y11.081 E13.77165 //Continue printing to (63.132, 11.081)E increments represent the amount of printing materials;
……...
其中“//”的内容为解释部分。The content of "//" is the explanation part.
则,当在其打印路径中存在一个P点(35.783,11.081),此时,在该点停留时典型代码如下:Then, when there is a P point (35.783, 11.081) in its printing path, the typical code when staying at this point is as follows:
……...
G1 X35.783 Y11.081 E13.44863//从(***,***)打印到(35.783,11.081);E表示打印丝材的总量(下同);G1 X35.783 Y11.081 E13.44863//print from (***,***) to (35.783,11.081); E represents the total amount of printing filament (the same below);
G1 X49.458 Y11.081 E13.61014//从(35.783,11.081)打印到(49.458,11.081)E的增量表示打印材料的用量;G1 X49.458 Y11.081 E13.61014//The increment from (35.783, 11.081) to (49.458, 11.081) E indicates the amount of printing material;
G4 P200     //在P点(49.458,11.081)处停留200MSG4 P200 //Stay at point P (49.458, 11.081) for 200MS
G1 X63.132Y11.081 E13.77165//继续打印到(63.132,11.081)G1 X63.132Y11.081 E13.77165//continue to print to (63.132, 11.081)
……...
本发明得到的制品具有使用3D打印制造的嵌件。其中,3D打印与注射成型可以使用相同的材料,也可以使用不同的材料。3D打印制品所使用的工艺可以是FDM、SLS、POLYJET、MJF、SLA等工艺的一种或多种形式的组合。The resulting article of the invention has an insert manufactured using 3D printing. Among them, 3D printing and injection molding can use the same material or different materials. The process used for 3D printing products can be one or a combination of FDM, SLS, POLYJET, MJF, SLA and other processes.
本发明还提供了上述3D打印与注射成型组合制品的具体应用,该类产品在力学性能、导电、导热性能的一个方面或多个方面具有优势。The present invention also provides a specific application of the above-mentioned combined product of 3D printing and injection molding, which has advantages in one or more aspects of mechanical properties, electrical conductivity, and thermal conductivity.
发明原理:本发明利用3D打印制件可以灵活设计制件结构的特点,设计出利于熔体在型腔内充填并保持取向的结构,实现聚合物注射成型制品在局部或全部空间上的性能调控。同时,使用停留点的办法使材料在停留点位置上会增加少量原料,从而在此处增大充填熔体与打印件之间的界面结合作用,The principle of the invention: the invention uses the characteristics of the 3D printed parts to flexibly design the structure of the part, and designs a structure that facilitates the filling of the melt in the cavity and maintains the orientation, so as to realize the performance control of the polymer injection molding product in part or all spaces . At the same time, the method of using the stop point will add a small amount of raw materials to the material at the position of the stop point, thereby increasing the interface bonding between the filling melt and the printed part,
虽然,注射成型生产效率高,可以加工外形复杂的产品,不仅可以适用于热塑性塑料,也可以适用于热固性塑料,因而,采用该工艺加工的产品应用十分广泛,目前是塑料制品工业化生产制造的一种常见工艺。不过,注射成型也经常面临着制件的局部增强、力学性能或者传导性能的提升等方面的需求。Although injection molding has high production efficiency and can process products with complex shapes, it can be applied not only to thermoplastics, but also to thermosetting plastics. Therefore, products processed by this process are widely used, and it is currently one of the industrial production methods for plastic products. a common process. However, injection molding is also often faced with the need for local reinforcement of parts, improvement of mechanical properties or conductivity.
而将3D打印和注射成型结合起来,具有如下技术难点:将3D打印制件放入注射模具内后进行注射充填时就也会面临一系列问题,3D打印制件无法较好的安放于注射模具内部;注射充填的压力较高时,3D打印制件可能无法承受而发生严重变形;3D打印制件与后充入熔体之间的界面结合较差;3D打印制件与注射制品的组合制件很容易发生翘 曲等。The combination of 3D printing and injection molding has the following technical difficulties: when the 3D printed parts are put into the injection mold and then injected and filled, they will also face a series of problems, and the 3D printed parts cannot be placed in the injection mold well. Internal; when the pressure of injection filling is high, the 3D printed part may not be able to bear it and cause severe deformation; the interface between the 3D printed part and the post-filled melt is poor; Parts are prone to warping, etc.
本发明提供了3D打印与注射成型组合制造的方法,全面解决了使用该方法进行组合制造时所面临的问题,通过优化最终制品结构设计、3D打印制件的结构设计、全套工艺方案及相关参数、相关装置及模具的设计等,获得力学性能、传导性能或其它使用性能的一个方面或多个方面超过普通注射制品的组合制件,该工艺的重复性好、可实施性强,适合于批量化生产。The present invention provides a method for combined manufacturing of 3D printing and injection molding, which comprehensively solves the problems faced when using this method for combined manufacturing. , the design of related devices and molds, etc., to obtain one or more aspects of mechanical properties, conductivity or other performance properties that exceed the combined parts of ordinary injection products. This process has good repeatability and strong implementability, and is suitable for batch production. chemical production.
采用本发明的3D打印与注射成型相互组合制造的方法,具有以下有益效果:The method of combining 3D printing and injection molding of the present invention has the following beneficial effects:
(1)可很容易的兼具3D打印与注射成型两种加工方法的优势,在提升制品全部或局部的力学性能、导热或导电性能方面具有广泛的应用前景;(1) It can easily combine the advantages of the two processing methods of 3D printing and injection molding, and has broad application prospects in improving the mechanical properties, thermal conductivity or electrical conductivity of the product in whole or in part;
(2)利用普通设备即可实现生产,使用和普通注射制品完全一致的模具,无需对模具结构进行修改或者调整,因而工艺简单、方便实施;(2) The production can be realized by using ordinary equipment, using a mold that is exactly the same as ordinary injection products, and there is no need to modify or adjust the mold structure, so the process is simple and convenient to implement;
(3)有效提高了异种材料之间的界面结合力,产品的一致性好;(3) The interfacial bonding force between dissimilar materials is effectively improved, and the consistency of the product is good;
(4)有效解决了3D打印件安放与固定于注射模具时容易出现的问题以及3D打印与注射成型组合制件很容易发生的翘曲问题等;(4) Effectively solve the problems that are easy to occur when 3D printing parts are placed and fixed on the injection mold, and the warping problems that are easy to occur when 3D printing and injection molding combined parts are easy to occur;
(5)在打印过程中增加的停留点可以不体现在其结构设计中,这些停留点是后来通过直接修改代码形成的,位置上随机分布,从而不会在宏观上产生对熔体流动的阻碍效应,也不会影响打印件自身的结构。(5) The added stop points in the printing process may not be reflected in its structural design. These stop points are formed by directly modifying the code later, and the positions are randomly distributed, so that there will be no hindrance to the flow of the melt on a macro level effect, and will not affect the structure of the print itself.
(6)本发明中相应3D打印制件的设计方法及代码改进方法,应用上述方法来调控聚合物注射流动过程的制品,该制品的力学性能、电学性能等明显超越同类制品。(6) The design method and code improvement method of the corresponding 3D printed parts in the present invention, the products that use the above methods to control the polymer injection flow process, the mechanical properties and electrical properties of the products obviously surpass similar products.
附图说明Description of drawings
图1是本发明的工艺过程示意图Fig. 1 is technological process schematic diagram of the present invention
图2是本发明的工艺路线示意图。Fig. 2 is a schematic diagram of the process route of the present invention.
图3是本发明的3D打印制件的设计图。Fig. 3 is a design drawing of the 3D printing part of the present invention.
图4是本发明实施例1所得3D打印制件的外形图,即具有微沟壑形式的3D打印嵌件。Fig. 4 is an outline view of the 3D printed part obtained in Example 1 of the present invention, that is, a 3D printed insert in the form of micro-grooves.
图5是本发明实施例2所得3D打印制件的外形图,即无沟壑形式的3D打印嵌件。Fig. 5 is an outline view of the 3D printed part obtained in Example 2 of the present invention, that is, the 3D printed insert without grooves.
图6是对比例1的制件外形图,具有宏观沟壑形式的3D打印嵌件。Fig. 6 is an outline view of the part of Comparative Example 1, which has a 3D printed insert in the form of a macroscopic ravine.
图7是对比例2的制件外形图,网格状打印件。Fig. 7 is the outline drawing of the workpiece of Comparative Example 2, a grid-like printed part.
图8是3D打印制件充入PP材料后所得制件;其中,图A为对比例1制件,该制件未经前预热及后处理,翘曲严重;图B为对比例1制件,该制件经过预热,但未经过后处理,翘曲稍好;图C为实施例1的制件,翘曲完全消除。Figure 8 is the product obtained after the 3D printed part is filled with PP material; Among them, Figure A is the product of Comparative Example 1, which has serious warping without preheating and post-treatment; Figure B is the product of Comparative Example 1 Part, the part has been preheated, but not post-treated, and the warpage is slightly better; Figure C is the part of Example 1, and the warpage is completely eliminated.
图9是本发明实施例制品的截面结构扫描电镜图。Fig. 9 is a scanning electron micrograph of the cross-sectional structure of the product of the embodiment of the present invention.
图10是对比例制品的截面结构扫描电镜图。Fig. 10 is a scanning electron micrograph of a cross-sectional structure of a comparative product.
具体实施方式Detailed ways
下面结合实施例对本发明进一步地详细描述。The present invention will be further described in detail below in conjunction with the examples.
本发明所述的3D打印与注射成型组合制造方法,主要包括前期准备和成型加工过程、以及后处理等三部分关键技术细节。设备方面,需要一台普通的注射机和3D打印机;使用的注射原料为热塑性树脂,3D打印原料根据其相应工艺确定,使用的原辅材料均为市售。The 3D printing and injection molding combined manufacturing method described in the present invention mainly includes three key technical details of preliminary preparation, molding process, and post-processing. In terms of equipment, an ordinary injection machine and 3D printer are required; the injection raw material used is thermoplastic resin, and the 3D printing raw material is determined according to its corresponding process, and the raw and auxiliary materials used are all commercially available.
如图1、2所示是本发明的工艺过程和路线示意图,本发明的主要实现步骤包括以下步骤:As shown in Fig. 1, 2 is technological process and route schematic diagram of the present invention, and main realization step of the present invention comprises the following steps:
(1)对欲加工的注射制件的结构进行分析,确定其特点及使用目标,并进而确定3D打印制件的嵌入位置、尺寸和形状特征,开展3D打印制件的结构设计;(1) Analyze the structure of the injection part to be processed, determine its characteristics and use goals, and then determine the embedding position, size and shape characteristics of the 3D printed part, and carry out the structural design of the 3D printed part;
(2)修改3D打印源代码,并完成3D打印制件的加工;(2) Modify the 3D printing source code and complete the processing of the 3D printing parts;
(3)将3D打印制件预热后放入注射模具相应位置内;(3) Preheat the 3D printed part and put it into the corresponding position of the injection mold;
(4)将热塑性聚合物原料充入注射模具内,经过冷却后,3D打印制件与后注射充入的聚合物原料形成均一的组合制件;(4) Fill the thermoplastic polymer raw material into the injection mold, and after cooling, the 3D printed part and the polymer raw material injected after injection form a uniform combined part;
(5)将所得的组合制件进行翘曲及应力分布的后处理,即可得到力学性能优异、或者具有特殊传导性能、或具有特殊调控效果的产品。(5) After post-processing the warpage and stress distribution of the obtained composite parts, products with excellent mechanical properties, or special conduction properties, or special control effects can be obtained.
实施例1 PC/ABS-FDM-微沟壑+PPExample 1 PC/ABS-FDM-micro-grooves+PP
本实施例为利用PC/ABS为3D打印原料,PP为注射原料,其中,PP的拉伸强度为27.5MPA,杨氏模量为1099MPa,PC/ABS打印件的拉伸强度为45.7MPa,杨氏模量为1975MPa。使用的3D打印工艺为FDM。其实施过程如下:In this example, PC/ABS is used as the raw material for 3D printing, and PP is used as the raw material for injection. Among them, the tensile strength of PP is 27.5MPA, the Young's modulus is 1099MPa, and the tensile strength of PC/ABS printed parts is 45.7MPa. The modulus is 1975MPa. The 3D printing process used is FDM. Its implementation process is as follows:
首先,开展3D打印制件的结构设计,其设计过程如图3所示,根据欲加工标准拉伸样条的特点,将3D打印制件的结构主要包括3部分,底部固定到模具的部分,其宽度控制在10.1mm,端部加强部分,宽度按10mm,以及细长流道部分,其截面部分占整个注射件截面体积在40%(含底部固定部分);该打印制件显示于图4之中,其中该制件左边部分为自身增强部分,制件的下部为模具内安放部分,制件的右边上部为熔体流动调控部分,在熔体流动调控部分有微细的沟壑存在。Firstly, carry out the structural design of the 3D printed part. The design process is shown in Figure 3. According to the characteristics of the standard tensile spline to be processed, the structure of the 3D printed part mainly includes three parts, the bottom part is fixed to the mold, Its width is controlled at 10.1mm, the end reinforcement part, the width is 10mm, and the elongated flow channel part, its cross-sectional part accounts for 40% of the cross-sectional volume of the entire injection part (including the bottom fixed part); the printed part is shown in Figure 4 Among them, the left part of the part is the self-reinforcing part, the lower part of the part is the placement part in the mold, and the upper right part of the part is the melt flow control part, and there are fine grooves in the melt flow control part.
其次,根据设计的模型,软件自动生成3D打印源代码,在此基础上,修改3D打印源代码,在其打印过程中,增强停留点,停留点具体的确定方法是:1)根据制品尺寸及性能目标,确定在间隔距离5到10毫米内增强一个停留点;2)在打印代码中,确定每一个间隔点位置及其代码;3)修改打印段的代码,插入停留点代码,并同步修改打印材料的用量。Secondly, according to the designed model, the software automatically generates the 3D printing source code. On this basis, the 3D printing source code is modified, and the stop point is enhanced during the printing process. The specific method for determining the stop point is: Performance goals, determine to enhance a stop point within the interval distance of 5 to 10 mm; 2) In the printing code, determine the position of each interval point and its code; 3) Modify the code of the printing section, insert the code of the stop point, and modify it synchronously The amount of printing material used.
比如,在打印过程中有如下代码:For example, there is the following code in the printing process:
…......
G1 X35.783 Y11.081 E13.44863//从(***,***)打印到(35.783,11.081);E表示打印丝材的总量(下同);G1 X35.783 Y11.081 E13.44863//print from (***,***) to (35.783,11.081); E represents the total amount of printing filament (the same below);
G1 X63.132 Y11.081 E13.77165//继续打印到(63.132,11.081)E的增量表示打印材料的用量;G1 X63.132 Y11.081 E13.77165//Continue printing to (63.132, 11.081)E increment indicates the amount of printing material;
…......
其中“//”的内容为解释部分。The content of "//" is the explanation part.
则,当在其打印路径中存在一个P点(35.783,11.081),此时,在该点停留时典型代码如下:Then, when there is a P point (35.783, 11.081) in its printing path, the typical code when staying at this point is as follows:
…......
G1 X35.783 Y11.081 E13.44863//从(***,***)打印到(35.783,11.081);E表示打印丝材的总量(下同);G1 X35.783 Y11.081 E13.44863//print from (***,***) to (35.783,11.081); E represents the total amount of printing filament (the same below);
G1 X49.458 Y11.081 E13.61014//从(35.783,11.081)打印到(49.458,11.081)E的增量表示打印材料的用量;G1 X49.458 Y11.081 E13.61014//The increment from (35.783, 11.081) to (49.458, 11.081) E indicates the amount of printing material;
G4 P200//在P点(49.458,11.081)处停留200MSG4 P200//Stay at point P (49.458, 11.081) for 200MS
G1 X63.132 Y11.081 E13.77165//继续打印到(63.132,11.081)G1 X63.132 Y11.081 E13.77165//continue to print to (63.132, 11.081)
…......
使用修改后的打印代码完成3D打印制件的加工;Use the modified printing code to complete the processing of 3D printing parts;
再次,将3D打印制件预热到130度后放入到温度为80度的注射模具内,此时,稍加用力可将打印件放置到模具内并实现轻松的固定;Again, preheat the 3D printed part to 130 degrees and put it into the injection mold with a temperature of 80 degrees. At this time, with a little force, the printed part can be placed in the mold and easily fixed;
之后,将PP原料充入注射模具内,经过冷却后,3D打印制件与后注射充入的聚合物原料形成均一的组合制件,其外形如图7所示;Afterwards, the PP raw material is filled into the injection mold, and after cooling, the 3D printed part and the polymer raw material injected after injection form a uniform combined part, and its appearance is shown in Figure 7;
最终,将所得的组合制件进行翘曲及应力分布的后处理,即对制件放置于和其形状相互适应的夹具中,并在低于熔点温度10~30度范围内保持5~20分钟,最终可得到力学性能优异、或者具有特殊传导性能、或具有特殊调控效果的产品。Finally, the resulting combined parts are subjected to warpage and post-processing of stress distribution, that is, the parts are placed in a fixture that is compatible with its shape, and kept at a temperature of 10 to 30 degrees below the melting point for 5 to 20 minutes Finally, products with excellent mechanical properties, or special conductivity properties, or special regulation effects can be obtained.
对所制得的制品进行拉伸性能测试,测试结果见表1。The prepared products were tested for tensile properties, and the test results are shown in Table 1.
从该结果可知,将3D打印与注射成型组合后所得制品的拉伸强度高达39.8MPa,杨氏模量为2041MPa。这个结果远超过理论结果(按两相律模型折算后的拉伸强度应该为34.78MPa,杨氏模量应该为1449MPa),从而表明了该工艺中两部分材料产生的协同效应,证实了该方法在提升力学性能方面的有效性。From the results, it can be seen that the tensile strength of the product obtained after combining 3D printing and injection molding is as high as 39.8 MPa, and the Young's modulus is 2041 MPa. This result far exceeds the theoretical result (the tensile strength after conversion according to the two-phase law model should be 34.78MPa, and the Young's modulus should be 1449MPa), thus indicating the synergistic effect of the two parts of the material in the process and confirming the method. Effectiveness in improving mechanical properties.
另外,也将组合制件中的3D打印部分去除后仅测试细长流道部分内的PP材料,发现该部分的PP的拉伸强度高达31.1MPa,和纯PP的拉伸强度27.5MPA相比,材料的性能明显提升,这可能与PP分子链在打印件内流动时受到明显的牵伸作用有关,从而表明本申请中3D打印件的结构有利于提升PP在流动方向上性能提升。In addition, after removing the 3D printing part in the composite part, only the PP material in the slender flow channel part was tested, and it was found that the tensile strength of the PP in this part was as high as 31.1MPa, compared with the pure PP tensile strength of 27.5MPA , the performance of the material is significantly improved, which may be related to the obvious drafting effect of the PP molecular chain when it flows in the printed part, which shows that the structure of the 3D printed part in this application is conducive to improving the performance of PP in the flow direction.
其内部结构显示打印材料与后注入材料之间的结合很紧密,这则是其力学性能提升的另一个主要原因,如图9所示。Its internal structure shows that the combination between the printing material and the post-injection material is very tight, which is another main reason for the improvement of its mechanical properties, as shown in Figure 9.
实施例2 PC/ABS-FDM-细长流道+PPExample 2 PC/ABS-FDM-slender flow channel+PP
本实施例为利用PC/ABS为3D打印原料,PP为注射原料,其中,PP的拉伸强度为27.5MPA,杨氏模量为1099MPa,PC/ABS打印件的拉伸强度为45.7MPa,杨氏模量为1975MPa。使用的3D打印工艺为FDM。其实施过程如下:In this example, PC/ABS is used as the raw material for 3D printing, and PP is used as the raw material for injection. Among them, the tensile strength of PP is 27.5MPA, the Young's modulus is 1099MPa, and the tensile strength of PC/ABS printed parts is 45.7MPa. The modulus is 1975MPa. The 3D printing process used is FDM. Its implementation process is as follows:
首先,开展3D打印制件的结构设计,其设计过程也如图3所示,根据欲加工标准拉伸样条的特点,将3D打印制件的结构主要包括3部分,底部固定到模具的部分,其宽度控制在10.1mm,端部加强部分,宽度按10mm,以及细长流道部分,其截面部分占整个注射件截面体积在45%(含底部固定部分);该打印制件显示于图5之中,其中该制件左边部分为自身增强部分,制件的下部为模具内安放部分,制件的右边上部为熔体流动调控部分,也即细长流道部分。该制件的基本结构与图4类似,但缺少微沟壑,其熔体流动调控部分的臂相对光滑。Firstly, carry out the structural design of the 3D printed part, and the design process is also shown in Figure 3. According to the characteristics of the standard tensile spline to be processed, the structure of the 3D printed part mainly includes three parts, the bottom part is fixed to the mold , its width is controlled at 10.1mm, the end reinforcement part, the width is 10mm, and the slender flow channel part, its cross-sectional part accounts for 45% of the entire cross-sectional volume of the injection part (including the bottom fixed part); the printed part is shown in Fig. 5, wherein the left part of the part is the self-reinforcing part, the lower part of the part is the placement part in the mold, and the upper right part of the part is the melt flow control part, that is, the slender runner part. The basic structure of the part is similar to that in Figure 4, but lacks micro-grooves, and the arms of the melt flow regulation part are relatively smooth.
其次,根据设计的模型,软件自动生成3D打印源代码,根据代码直接打印出制件,如图4所示。Secondly, according to the designed model, the software automatically generates the 3D printing source code, and directly prints out the part according to the code, as shown in Figure 4.
再次,将3D打印制件预热到120度后放入到温度为90度的注射模具内,此时,稍加用力可将打印件放置到模具内并实现轻松的固定;Again, preheat the 3D printed part to 120 degrees and put it into the injection mold with a temperature of 90 degrees. At this time, with a little force, the printed part can be placed in the mold and easily fixed;
之后,将PP原料充入注射模具内,经过冷却后,3D打印制件与后注射充入的聚合物原料形成均一的组合制件,其外形也如图7所示;Afterwards, the PP raw material is filled into the injection mold, and after cooling, the 3D printed part and the polymer raw material injected after injection form a uniform combined part, and its appearance is also shown in Figure 7;
最终,将所得的组合制件进行翘曲及应力分布的后处理,即对制件放置于和其形状相互适应的夹具中,并在低于熔点温度10~30度范围内保持5~20分钟,依据打印件的不同性能特点,最终可得到力学性能优异、或者具有特殊传导性能、或具有特殊调控效果的产品。Finally, the resulting combined parts are subjected to warpage and post-processing of stress distribution, that is, the parts are placed in a fixture that adapts to its shape, and kept at a temperature of 10 to 30 degrees below the melting point for 5 to 20 minutes According to the different performance characteristics of the printed parts, products with excellent mechanical properties, or special conductivity properties, or special control effects can be obtained.
对所制得的制品进行拉伸性能测试,测试结果也见表1。The tensile performance test was carried out on the prepared product, and the test results are also shown in Table 1.
从该结果可知,将3D打印与注射成型组合后所得制品的拉伸强度高达38.5MPa,杨氏模量为1997MPa。这个结果远超过理论结果(按两相律模型折算的拉伸强度应该为35.69MPa,杨氏模量应该为1493MPa),从而表明了该工艺中两部分材料产生的协同效应,证实了该方法在提升力学性能方面的有效性。From the results, it can be seen that the tensile strength of the product obtained after combining 3D printing and injection molding is as high as 38.5 MPa, and the Young's modulus is 1997 MPa. This result far exceeds the theoretical result (the tensile strength converted according to the two-phase law model should be 35.69MPa, and the Young's modulus should be 1493MPa), thus indicating the synergistic effect produced by the two parts of the material in the process, and confirming that the method is effective in Improve the effectiveness of mechanical properties.
另外,也将组合制件中的3D打印部分去除后仅测试细长流道部分内的PP材料,发现该部分的PP的拉伸强度高达30.9MPa,和纯PP的拉伸强度27.5MPA相比,材料的性能明显提升,这可能与PP分子链在打印件内流动时受到明显的牵伸作用有关,从而表明本申请中3D打印件的结构有利于提升PP在流动方向上性能提升。In addition, after removing the 3D printing part of the composite part, only the PP material in the slender flow channel part was tested, and it was found that the tensile strength of PP in this part was as high as 30.9MPa, compared with 27.5MPa of pure PP , the performance of the material is significantly improved, which may be related to the obvious drafting effect of the PP molecular chain when it flows in the printed part, which shows that the structure of the 3D printed part in this application is conducive to improving the performance of PP in the flow direction.
为了对本发明的效果进行说明,另外列举了相应的注射制品和常规三维打印制品的 力学性能作为对比,比较结果也列于表1。In order to illustrate the effect of the present invention, the mechanical properties of corresponding injection products and conventional three-dimensional printing products are listed as a comparison, and the comparison results are also listed in Table 1.
对比例1 PC/ABS-FDM-宏观沟壑+PPComparative example 1 PC/ABS-FDM-macro gully+PP
对比例1主要与实施例1中的代码停留效果相对比。其主要方法是将实施例1中的代码停留直接在打印件中设计一些宏观的沟壑,如图6所示,但这些沟壑的存在反而会破坏熔体的流动,从而表现出在制件性能提升上的不足。Comparative Example 1 is mainly compared with the code retention effect in Example 1. The main method is to stay the code in Example 1 and design some macroscopic grooves directly in the printed part, as shown in Figure 6, but the existence of these grooves will destroy the flow of the melt instead, thus showing the improvement in the performance of the part Insufficient on.
对比例2 PC/ABS-FDM-网格+PPComparative example 2 PC/ABS-FDM-grid+PP
对比例2主要与实施例2相互对比,其3D打印件设计为网格状,这个结构很容易设计及打印,所得打印制件的外形如图7所示,经过和实施例2完全相同的工艺后,所得制品的拉伸强度仅为29.1MPa,杨氏模量为1489MPa。Comparative Example 2 is mainly compared with Example 2. The 3D printed part is designed in a grid shape. This structure is easy to design and print. The appearance of the printed part is shown in Figure 7. After the same process as in Example 2 Finally, the tensile strength of the obtained product is only 29.1MPa, and the Young's modulus is 1489MPa.
表1 几种制品的拉伸性能比较Table 1 Comparison of tensile properties of several products
Figure PCTCN2022076285-appb-000001
Figure PCTCN2022076285-appb-000001
通过表1的数据也可以看出,本发明的制品的力学性能有很大的提高,因而这类制品具有性能优异的特点,从而具有优异的应用前景。It can also be seen from the data in Table 1 that the mechanical properties of the product of the present invention are greatly improved, so this type of product has the characteristics of excellent performance and thus has excellent application prospects.
另外,也将实施例1和对比例1的制品外形列于图8中,从图8可知,实施例1中所得制品的翘曲被消除,而对比例1制品翘曲严重。另外,也将实施例1和对比例2的制品内部结构分别列于图9和图10中,从图的对比可知,实施例1所得的3D打印件与注射熔体之间结合紧密,而对比例2则显示的3D打印件与注射熔体之间有明显的缝隙,表明两者的界面作用力较差。上述表明本发明的实施效果明显。In addition, the profiles of the products of Example 1 and Comparative Example 1 are also listed in Figure 8. From Figure 8, it can be seen that the warping of the product obtained in Example 1 is eliminated, while the product of Comparative Example 1 has serious warping. In addition, the internal structures of the products of Example 1 and Comparative Example 2 are also listed in Figure 9 and Figure 10 respectively. From the comparison of the figures, it can be seen that the 3D printed parts obtained in Example 1 are closely bonded to the injected melt, while for Scale 2 shows that there is an obvious gap between the 3D printed part and the injected melt, indicating that the interface force between the two is poor. The above shows that the implementation effect of the present invention is obvious.
实施例3 导电ABS-FDM-微沟壑+PPExample 3 Conductive ABS-FDM-micro-groove+PP
本实施例利用市售导电级ABS为3D打印原料,PP为注射原料。其实施过程与实施例1保持一致。最终所得的组合制件在厚度与宽度方向上的导电性能比PP大幅提升,表 现为导电ABS的性能,而且其力学性能也具有与实施例1类似的效果。In this embodiment, commercially available conductive grade ABS is used as the raw material for 3D printing, and PP is used as the raw material for injection. Its implementation process is consistent with embodiment 1. The electrical conductivity of the finally obtained combined part in the thickness and width directions is greatly improved than that of PP, showing the performance of conductive ABS, and its mechanical properties also have effects similar to those of Example 1.
实施例4 PA-SLS-细长流道+PPExample 4 PA-SLS-slender flow channel+PP
本实施例为利用PA为3D打印原料,PP为注射原料,其中,PP的拉伸强度为27.5MPA,杨氏模量为1099MPa,PA打印件的拉伸强度为46.2MPa,杨氏模量为1591MPa。使用的3D打印工艺为粉末激光烧结SLS。其实施过程与实施例2一致。In this example, PA is used as the raw material for 3D printing, and PP is used as the raw material for injection. Among them, the tensile strength of PP is 27.5MPa, the Young's modulus is 1099MPa, the tensile strength of PA printed parts is 46.2MPa, and the Young's modulus is 1591 MPa. The 3D printing process used is powder laser sintering SLS. Its implementation process is consistent with embodiment 2.
对所制得的制品进行拉伸性能测试,结果可知,将3D打印与注射成型组合后所得制品的拉伸强度高达40.2MPa,杨氏模量为1489MPa,其结果明显超过纯PP的力学性能,也超过按两相律模型计算后所得的理论值(按两相律模型折算的拉伸强度应为35.91MPa,拉伸模量应该为1320MPa)。The tensile performance test of the prepared product shows that the tensile strength of the product obtained after combining 3D printing and injection molding is as high as 40.2MPa, and the Young's modulus is 1489MPa, which obviously exceeds the mechanical properties of pure PP. It also exceeds the theoretical value calculated by the two-phase law model (the tensile strength converted by the two-phase law model should be 35.91MPa, and the tensile modulus should be 1320MPa).
另外,也将组合制件中的3D打印部分去除后仅测试细长流道部分内的PP材料,发现该部分的PP的拉伸强度高达30.8MPa,和纯PP的拉伸强度27.5MPA相比,材料的性能明显提升,这可能与PP分子链在打印件内流动时受到明显的牵伸作用有关,从而表明本申请中3D打印件的结构有利于提升PP在流动方向上性能提升。In addition, after removing the 3D printing part in the composite part, only the PP material in the slender flow channel part was tested, and it was found that the tensile strength of PP in this part was as high as 30.8MPa, compared with 27.5MPa of pure PP , the performance of the material is significantly improved, which may be related to the obvious drafting effect of the PP molecular chain when it flows in the printed part, which shows that the structure of the 3D printed part in this application is conducive to improving the performance of PP in the flow direction.
对比例3 PA-SLS-网格+PPComparative example 3 PA-SLS-grid+PP
本对比例使用的原料和实施例4相同,3D打印制件的结构设计与对比例2一致,经过和实施例4完全相同的工艺后,所得制品的拉伸强度仅为36.2MPa,杨氏模量为1336MPa,因而表明实施例4对力学性能的提升效果比较明显。The raw materials used in this comparative example are the same as in Example 4, and the structural design of the 3D printed part is consistent with that of Comparative Example 2. After the same process as in Example 4, the tensile strength of the obtained product is only 36.2MPa, Young’s modulus The weight is 1336MPa, thus shows that embodiment 4 is more obvious to the promoting effect of mechanical property.

Claims (10)

  1. 一种基于3D打印和注射成型的制造方法,其特征在于,包括以下步骤:A manufacturing method based on 3D printing and injection molding, is characterized in that, comprises the following steps:
    (1)对3D打印制件进行结构设计,并完成3D打印制件的加工;(1) Design the structure of the 3D printed parts and complete the processing of the 3D printed parts;
    (2)将3D打印制件预热后放入注射模具相应位置内;(2) Preheat the 3D printed part and put it into the corresponding position of the injection mold;
    (3)将热塑性聚合物原料充入注射模具内,经过冷却后定型,3D打印制件与后注射充入的聚合物原料形成均一的组合制件;(3) Fill the thermoplastic polymer raw material into the injection mold, and shape it after cooling, and the 3D printed part and the polymer raw material injected after injection form a uniform combined part;
    (4)将所得的组合制件进行翘曲及应力分布的后处理,即得。(4) After the warpage and stress distribution are performed on the obtained combined parts, it is obtained.
  2. 根据权利要求1所述的基于3D打印和注射成型的制造方法,其特征在于,步骤(1)中,根据欲加工的注射制件的结构进行分析,确定其特点及使用目标,并进而确定3D打印制件的嵌入位置、尺寸和形状特征,开展3D打印制件的结构设计。According to the manufacturing method based on 3D printing and injection molding according to claim 1, it is characterized in that in step (1), analyze according to the structure of the injection part to be processed, determine its characteristics and use targets, and then determine the 3D The embedding position, size and shape characteristics of the printed parts, and the structural design of the 3D printed parts.
  3. 根据权利要求2所述的基于3D打印和注射成型的制造方法,其特征在于,3D打印制件的结构设计包括自身结构增强部分、模内安放部分和熔体流动调控部分;其中,自身结构增强部分保证打印件在注射模腔内承受0~50MPa压力时不发生变形,模内安放部分比模具型腔相应位置的尺寸大0.5%~2%,熔体流动调控部分与熔体在注射过程中的流动相互适应。The manufacturing method based on 3D printing and injection molding according to claim 2, wherein the structural design of the 3D printed part includes a self-structural reinforcement part, an in-mold placement part and a melt flow control part; wherein, the self-structural reinforcement Partially guarantee that the printed parts will not deform when they are subjected to a pressure of 0-50MPa in the injection mold cavity. The part placed in the mold is 0.5% to 2% larger than the size of the corresponding position in the mold cavity. flows adapt to each other.
  4. 根据权利要求1所述的基于3D打印和注射成型的制造方法,其特征在于,步骤(2)中,3D打印制件预热温度低于其热变形温度5~20度之间,并且预热温度和注射模具的温度差值在0度~80度之间。The manufacturing method based on 3D printing and injection molding according to claim 1, characterized in that in step (2), the preheating temperature of the 3D printed part is between 5 and 20 degrees lower than its heat distortion temperature, and the preheating The difference between the temperature and the temperature of the injection mold is between 0 degrees and 80 degrees.
  5. 根据权利要求1所述的基于3D打印和注射成型的制造方法,其特征在于,步骤(4)中,后处理包括将制件放置于与所述制件形状相匹配的夹具中,并在低于熔点温度10~20度范围内保持5-20分钟。The manufacturing method based on 3D printing and injection molding according to claim 1, characterized in that in step (4), the post-processing includes placing the workpiece in a fixture that matches the shape of the workpiece, and Keep it in the melting point range of 10-20 degrees for 5-20 minutes.
  6. 根据权利要求3所述的基于3D打印和注射成型的制造方法,其特征在于,3D打印件的熔体流动调控部分设有流道。The manufacturing method based on 3D printing and injection molding according to claim 3, characterized in that, the melt flow control part of the 3D printed part is provided with flow channels.
  7. 根据权利要求6所述的基于3D打印和注射成型的制造方法,其特征在于,流道的内壁表面设有微沟壑,所述微沟壑的加工方法为:在打印过程中设置位置随机的打印停留点,其停留时间在1~1000ms之间。According to the manufacturing method based on 3D printing and injection molding according to claim 6, it is characterized in that the inner wall surface of the flow channel is provided with micro-grooves, and the processing method of the micro-grooves is: during the printing process, a printing stop at a random position is set. point, and its dwell time is between 1 and 1000ms.
  8. 根据权利要求1所述的基于3D打印和注射成型的制造方法,其特征在于,步骤(1)中,3D打印制件的加工包括一种可增加打印停留点的3D打印代码修改方法,具体包括以下步骤:The manufacturing method based on 3D printing and injection molding according to claim 1, characterized in that in step (1), the processing of 3D printed parts includes a 3D printing code modification method that can increase the printing stop point, specifically including The following steps:
    (1)确定停留点间隔距离;(1) Determine the interval distance between the stop points;
    (2)根据每一个打印段确定间隔点数量;(2) Determine the number of interval points according to each printing segment;
    (3)确定每一个间隔点位置;(3) determine the position of each interval point;
    (4)修改打印段的代码,插入N个停留点代码。(4) Modify the code of the printing section and insert N codes of the stop points.
  9. 根据权利要求1所述的基于3D打印和注射成型的制造方法,其特征在于,3D打 印的成型工艺为FDM、SLS、POLYJET、MJF、SLA中的至少一种。The manufacturing method based on 3D printing and injection molding according to claim 1, wherein the molding process of 3D printing is at least one of FDM, SLS, POLYJET, MJF, and SLA.
  10. 一种权利要求1~9中任一项制造方法得到的制件在高性能或功能化注射成型制品上的应用。An application of the product obtained by the manufacturing method according to any one of claims 1 to 9 to high-performance or functional injection molded products.
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