WO2023234905A1 - Adaptive slicing and variable binder jetting method in binder jetting technique - Google Patents

Adaptive slicing and variable binder jetting method in binder jetting technique Download PDF

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Publication number
WO2023234905A1
WO2023234905A1 PCT/TR2023/050511 TR2023050511W WO2023234905A1 WO 2023234905 A1 WO2023234905 A1 WO 2023234905A1 TR 2023050511 W TR2023050511 W TR 2023050511W WO 2023234905 A1 WO2023234905 A1 WO 2023234905A1
Authority
WO
WIPO (PCT)
Prior art keywords
binder
layer thickness
amount
slicing
binder jetting
Prior art date
Application number
PCT/TR2023/050511
Other languages
French (fr)
Inventor
Hasan BAS
Fatih YAPICI
Ibrahim INANC
Original Assignee
Ondokuz Mayis Universitesi
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from TR2022/009076 external-priority patent/TR2022009076A2/en
Application filed by Ondokuz Mayis Universitesi filed Critical Ondokuz Mayis Universitesi
Publication of WO2023234905A1 publication Critical patent/WO2023234905A1/en

Links

Classifications

    • 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
    • B22F10/14—Formation of a green body by jetting of binder onto a bed of metal 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/31—Calibration of process steps or apparatus settings, e.g. before or during manufacturing
    • 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
    • B22F10/30—Process control
    • B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes

Definitions

  • the invention relates to the use of adaptive slicing in the binder jetting technique and to a method that provides different amount of binder to be sent according to the variable layer thickness.
  • Binder jetting technique is an additive manufacturing method.
  • constant layer thickness is used. That is, all layers are of the same thickness.
  • the adaptive slicing method is generally used in the fused filament fabrication (or fused deposition modelling) technique, which is another additive manufacturing method.
  • Adaptive slicing provides slicing of the three-dimensional model in the computer environment with variable layer thicknesses. Adaptive slicing provides surface quality and production time optimization.
  • a constant layer thickness is used in the normal binder jetting method.
  • the layer thickness must be thin. Thin layer thickness, on the other hand, prolongs the production time, which negatively affects the cost and production capacity. Thick layer thickness should be chosen to increase the production speed. However, in this case, the surface quality decreases.
  • jetting includes adjusting the amount of binder jetted onto a layer of powder feedstock depending on whether an outer portion of the 2D sheet shape or an inner portion of the 2D sheet shape is formed.
  • Adaptive slicing is not included in this document. In other words, the layer thickness is constant. It is only intended to jet a different amount of binder on the wall areas and interior areas of the part.
  • the recoaters comprise a controllably vibrated travelling powder dispenser having a hopper section adapted to contain the build powder, an opening through which the powder can be controllably discharged laterally into a chamber which is located beside the opening, and which has a mesh covering at least a portion of its bottom.
  • the invention aims using adaptive slicing in the binder jetting technique in 3D printers and relates to a method that provides a variable amount of binder to be sent according to the variable layer thickness.
  • the most important purpose of the invention is to provide a thick layer as the surface quality problem will not occur in steep regions, and to assign a thinner layer thickness as the staircase effect and surface quality problem will occur in inclined or angled regions. Thus, time and surface quality optimization is achieved.
  • Another aim of the invention is to provide a variable amount of binder to be sent according to the variable layer thickness. In this way, high surface quality products will be produced in a short time.
  • Another object of the invention is to enable adaptive slicing to be adapted to the binder jetting technique.
  • the binder jetting technique constant layer thickness is used.
  • adaptive slicing the layer thickness is variable. In this way, thick layer is applied in the areas where thin layer is not required in the required areas. In this way, it is possible to produce quickly without sacrificing part quality.
  • Figure -1 is the drawing providing the schematic view of the method that is the subject of the invention.
  • the microprocessor determining the current layer thickness by subtracting the Z coordinate from the previous Z coordinate 140. the microprocessor diving the current layer thickness by the calibrated layer thickness
  • the microprocessor determining the required amount of binder by multiplying the result obtained by dividing the current layer thickness by the calibrated layer thickness, by the amount of binder obtained as a result of the calibration
  • the microprocessor sending the amount of binder determined to be jetted.
  • the invention aims using adaptive slicing in the binder jetting technique in 3D printers and relates to a method that provides a variable amount of binder to be sent according to the variable layer thickness.
  • FIG. 2 shows the difference between normal slicing and adaptive slicing.
  • A. stands for solid model
  • B. for normal slicing
  • C. for adaptive slicing.
  • it is aimed to use adaptive slicing in the binder jetting technique and it is ensured that a variable amount of binder is sent according to the variable layer thickness. In this way, high surface quality products will be produced in a short time.
  • the amount of binder is directly related to the layer thickness. At different layer thicknesses, different amounts of binder must be jetted. If too much binder is sent, the surface quality deteriorates. Even if insufficient amount of binder is sent, no bond will form between the layers. Layer thicknesses are variable in adaptive slicing. In the preliminary tests, the constant amount of binder in adaptive slicing was tried and problems were encountered and the samples could not be produced properly. Different amounts of binder must be sent for layers of different thickness. Therefore, the present invention provides for jetting different amounts of binder at different layer thicknesses. As with any printer, it is necessary to determine the calibrated layer thickness and the amount of calibrated binder. For this, for example, let's choose a layer thickness of 0.1 mm.
  • the amount of binder in cm 2 /gr need not be given here. It can also be expressed in different ways. It can be completely unit-free.
  • the microprocessor reads the Z coordinates from the g-codes (e.g. 5.2). Then, read Z coordinate is subtracted from the previous Z coordinate data (e.g. 5.15).
  • the layer thickness is determined (0.05 mm).
  • the determined amount of binder is sent to be jetted. The same method is run for each different layer and the variable amount of binder is determined.
  • the method that is the subject of the invention comprises the process steps of;
  • the microprocessor determining the required amount of binder by multiplying the result obtained by dividing the current layer thickness by the calibrated layer thickness, by the amount of binder obtained as a result of the calibration (150), - the microprocessor sending the amount of binder determined to be jetted (160).

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Automation & Control Theory (AREA)

Abstract

The invention relates to the use of adaptive slicing in the binder jetting technique and to a method that provides different amount of binder to be sent according to the variable layer thickness.

Description

ADAPTIVE SLICING AND VARIABLE BINDER JETTING METHOD IN BINDER JETTING TECHNIQUE
Technical field of the invention
The invention relates to the use of adaptive slicing in the binder jetting technique and to a method that provides different amount of binder to be sent according to the variable layer thickness.
State of the Art
Binder jetting technique is an additive manufacturing method. In the additive manufacturing technique, constant layer thickness is used. That is, all layers are of the same thickness. The adaptive slicing method is generally used in the fused filament fabrication (or fused deposition modelling) technique, which is another additive manufacturing method. Adaptive slicing provides slicing of the three-dimensional model in the computer environment with variable layer thicknesses. Adaptive slicing provides surface quality and production time optimization.
A constant layer thickness is used in the normal binder jetting method. In order to produce quality products, the layer thickness must be thin. Thin layer thickness, on the other hand, prolongs the production time, which negatively affects the cost and production capacity. Thick layer thickness should be chosen to increase the production speed. However, in this case, the surface quality decreases.
In additive manufacturing methods, in order to produce a three-dimensional solid model, it must first be sliced through slicing programs. Three-dimensional printers provide part production with g-codes created according to these slices. In the binder jetting technique, normal slicing is used. In normal slicing, layer thicknesses are constant. In order to produce quickly, the layer thickness must be large in normal slicing. However, in this case, a situation called the staircase effect is encountered in the literature. This is undesirable and reduces the surface quality. In order to eliminate the staircase effect, the layers must be thin in normal slicing, but in this case the production time is greatly increased. To optimize this situation, the adaptive slicing method has been developed.
The invention that is the subject of the application no "US20190047047A1” in the state of the art describes how a binder can be jetted onto successive sinterable powder feedstock layers to form the 3D shape of a desired 3D green part, associated sintering supports and a corresponding shrinkage platform, for the separation and sintering of 3D printing green parts. According to one embodiment, jetting includes adjusting the amount of binder jetted onto a layer of powder feedstock depending on whether an outer portion of the 2D sheet shape or an inner portion of the 2D sheet shape is formed. Adaptive slicing is not included in this document. In other words, the layer thickness is constant. It is only intended to jet a different amount of binder on the wall areas and interior areas of the part.
In the invention that is the subject of the application no "JP2019516585” in the state of the art, a powder coater for use in three-dimensional printing and a three-dimensional printer with such a powder coater are described. The recoaters comprise a controllably vibrated travelling powder dispenser having a hopper section adapted to contain the build powder, an opening through which the powder can be controllably discharged laterally into a chamber which is located beside the opening, and which has a mesh covering at least a portion of its bottom.
The documents in the state of the art do not include methods that eliminate the staircase effect. For this reason, there is a need for a method that can assign variable layer thicknesses according to the shape of the solid model in the adaptive slicing method.
As a result, due to the negativities described above and the inadequacy of the existing solutions on the subject, it was necessary to make an improvement in the relevant technical field.
The aim of the invention
The invention aims using adaptive slicing in the binder jetting technique in 3D printers and relates to a method that provides a variable amount of binder to be sent according to the variable layer thickness. The most important purpose of the invention is to provide a thick layer as the surface quality problem will not occur in steep regions, and to assign a thinner layer thickness as the staircase effect and surface quality problem will occur in inclined or angled regions. Thus, time and surface quality optimization is achieved.
Another aim of the invention is to provide a variable amount of binder to be sent according to the variable layer thickness. In this way, high surface quality products will be produced in a short time.
Another object of the invention is to enable adaptive slicing to be adapted to the binder jetting technique. In the binder jetting technique, constant layer thickness is used. In adaptive slicing, the layer thickness is variable. In this way, thick layer is applied in the areas where thin layer is not required in the required areas. In this way, it is possible to produce quickly without sacrificing part quality.
The structural and characteristic features of the invention and all its advantages will be understood more clearly by the figures given below and the detailed description written with reference to these figures. For this reason, the evaluation should be made by taking these figures and detailed description into consideration.
Description of drawings:
Figure -1 : is the drawing providing the schematic view of the method that is the subject of the invention.
Reference numerals:
100. adaptive slicing in a binder jetting technique and variable binder jetting method
110. entering the calibrated layer thickness and the ideal amount of binder for the calibrated layer thickness in the printer device interface
120. the microprocessor reading Z coordinates from g-codes
130. the microprocessor determining the current layer thickness by subtracting the Z coordinate from the previous Z coordinate 140. the microprocessor diving the current layer thickness by the calibrated layer thickness
150. the microprocessor determining the required amount of binder by multiplying the result obtained by dividing the current layer thickness by the calibrated layer thickness, by the amount of binder obtained as a result of the calibration
160. the microprocessor sending the amount of binder determined to be jetted.
A. Solid model
B. Normal slicing
C. Adaptive slicing
Description of the invention
The invention aims using adaptive slicing in the binder jetting technique in 3D printers and relates to a method that provides a variable amount of binder to be sent according to the variable layer thickness.
In order to eliminate the staircase effect, the layers must be thin in normal slicing, but in this case the production time is greatly increased. To optimize this situation, the adaptive slicing method has been developed. In the adaptive slicing method, variable layer thicknesses are assigned according to the shape of the solid model. Since there will not be a big surface quality problem in steep areas, thinner layer thickness will be assigned as staircase effect and surface quality problem will occur in thick layer and inclined or angled areas Thus, time and surface quality optimization is achieved. Figure 2 shows the difference between normal slicing and adaptive slicing. In Figure 2, A. stands for solid model, B. for normal slicing, and C. for adaptive slicing. In the invention, it is aimed to use adaptive slicing in the binder jetting technique and it is ensured that a variable amount of binder is sent according to the variable layer thickness. In this way, high surface quality products will be produced in a short time.
The amount of binder is directly related to the layer thickness. At different layer thicknesses, different amounts of binder must be jetted. If too much binder is sent, the surface quality deteriorates. Even if insufficient amount of binder is sent, no bond will form between the layers. Layer thicknesses are variable in adaptive slicing. In the preliminary tests, the constant amount of binder in adaptive slicing was tried and problems were encountered and the samples could not be produced properly. Different amounts of binder must be sent for layers of different thickness. Therefore, the present invention provides for jetting different amounts of binder at different layer thicknesses. As with any printer, it is necessary to determine the calibrated layer thickness and the amount of calibrated binder. For this, for example, let's choose a layer thickness of 0.1 mm. If by testing for a layer thickness of 0.1 mm and it was decided that a binder of 2 cm2/g is required for the ideal situation, the amount of binder in cm2/gr need not be given here. It can also be expressed in different ways. It can be completely unit-free. In order to use this 0.1 mm layer thickness and 2 cm2/gr adhesive amount as calibration data, it is necessary to enter the calibrated layer thickness and the ideal binder amount for the calibrated layer thickness (110) in the printer device interface. The method starts working just before jetting the binder. Then the microprocessor reads the Z coordinates from the g-codes (e.g. 5.2). Then, read Z coordinate is subtracted from the previous Z coordinate data (e.g. 5.15). Thus, the layer thickness is determined (0.05 mm). The layer thickness is then divided by the calibrated layer thickness (obtaining 0.05/0.1 = 0.5). The result obtained is multiplied by the amount of calibrated binder (2*0.5 = 1 ) and the amount of binder is determined. The determined amount of binder is sent to be jetted. The same method is run for each different layer and the variable amount of binder is determined.
The method that is the subject of the invention comprises the process steps of;
- entering the calibrated layer thickness and the ideal amount of binder for the calibrated layer thickness in the printer device interface (1 10),
- the microprocessor reading Z coordinates from g-codes (120),
- the microprocessor determining the current layer thickness by subtracting the Z coordinate from the previous Z coordinate (130),
- the microprocessor diving the current layer thickness by the calibrated layer thickness (140),
- the microprocessor determining the required amount of binder by multiplying the result obtained by dividing the current layer thickness by the calibrated layer thickness, by the amount of binder obtained as a result of the calibration (150), - the microprocessor sending the amount of binder determined to be jetted (160).

Claims

CLAIMS: Adaptive slicing and variable binder jetting method in a binder jetting technique that enables the use of adaptive slicing in binder jetting technique in 3D printers (100), comprising the process steps of:
- entering the calibrated layer thickness and the ideal amount of binder for the calibrated layer thickness in the printer device interface (1 10),
- the microprocessor reading Z coordinates from g-codes (120),
- the microprocessor determining the current layer thickness by subtracting the Z coordinate from the previous Z coordinate (130),
- the microprocessor diving the current layer thickness by the calibrated layer thickness (140),
- the microprocessor determining the required amount of binder by multiplying the result obtained by dividing the current layer thickness by the calibrated layer thickness, by the amount of binder obtained as a result of the calibration (150),
- the microprocessor sending the amount of binder determined to be jetted (160) operation.
PCT/TR2023/050511 2022-06-02 2023-06-01 Adaptive slicing and variable binder jetting method in binder jetting technique WO2023234905A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
TR2022009076 2022-06-02
TR2022/009076 TR2022009076A2 (en) 2022-06-02 Adaptive slicing and variable adhesive spraying method in adhesive spraying technique.

Publications (1)

Publication Number Publication Date
WO2023234905A1 true WO2023234905A1 (en) 2023-12-07

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6596224B1 (en) * 1996-05-24 2003-07-22 Massachusetts Institute Of Technology Jetting layers of powder and the formation of fine powder beds thereby
US20170297106A1 (en) * 2016-04-14 2017-10-19 Desktop Metal, Inc. System for fabricating an interface layer to separate binder jetted objects from support structures
WO2019113412A1 (en) * 2017-12-07 2019-06-13 General Electric Company Binder jetting apparatus and methods

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6596224B1 (en) * 1996-05-24 2003-07-22 Massachusetts Institute Of Technology Jetting layers of powder and the formation of fine powder beds thereby
US20170297106A1 (en) * 2016-04-14 2017-10-19 Desktop Metal, Inc. System for fabricating an interface layer to separate binder jetted objects from support structures
WO2019113412A1 (en) * 2017-12-07 2019-06-13 General Electric Company Binder jetting apparatus and methods

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