Conformal manufacture method for 3D printing with high-viscosity material

Abstract

The present disclosure discloses a conformal manufacture method for 3D printing with high-viscosity material. The method comprises the steps: using 3D design software to design a 3D model of a component and a conformal contactless support; importing the 3D model data of the component and the conformal contactless support into slice software; importing multiple slice data of the component and the conformal contactless support into a 3D printing device, and sequentially scanning a high-viscosity material by laser till completing the printing; and removing the support and the uncured materials to finally obtain the component. The support and the component to be manufactured are easy to be separated, and no trace is left on the surface of the component. The present disclosure provides a conformal contactless support method for manufacturing a component having a complex bottom surface structure by using a 3D printing technology, and has a wide application prospect in the field of 3D manufacture.

Claims

1. A conformal manufacture method for 3D printing with high-viscosity material, wherein the method comprises the following steps: step 1, using 3D design software to design a 3D model of a component and a support to obtain 3D model data of the component and the support, wherein a gap with a certain thickness is arranged between the support and the component, and an upper surface of the support conforms to a lower surface of the component; step 2, importing the obtained 3D model data of the component and the support into slice software to obtain multiple slice data of the component and the support; step 3, importing the multiple slice data of the component and the support into a 3D printing device, and sequentially scanning a high-viscosity material by laser till to obtain the component and the support by printing, wherein the component and the support are solid under laser irradiation, and the gap is not irradiated by the laser so as to maintain original shape and properties of the high-viscosity material; and step 4, removing the support and the uncured materials to finally obtain the component, wherein the high-viscosity material is a photosensitive material, and its viscosity range is between 1000 cps and 1000000 cps.

2. The conformal manufacture method for 3D printing with high-viscosity material according to claim 1, wherein the support is formed by a conformal contactless support.

3. The conformal manufacture method for 3D printing with high-viscosity material according to claim 1, wherein the shape and size of the support can be adjusted according to the morphology of a bottom surface of the component to be printed.

4. The conformal manufacture method for 3D printing with high-viscosity material according to claim 1, wherein the high-viscosity material in the gap is deposited by extruding, scraping or spraying.

5. The conformal manufacture method for 3D printing with high-viscosity material according to claim 1, wherein printing parameters of the support and printing parameters of the component are the same.

6. The conformal manufacture method for 3D printing with high-viscosity material according to claim 1, wherein printing parameters of the support and printing parameters of the component are different.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) To describe the technical solutions in the embodiments of the present disclosure more clearly, the following briefly introduces the accompanying drawings for describing the embodiments. Apparently, the accompanying drawings in the following description show merely some embodiments of the present disclosure, and a person of ordinary skill in the art may still derive other drawings from these accompanying drawings without creative efforts.

(2) FIG. 1 is a ceramic denture obtained by the prior art after a support is removed.

(3) FIG. 2 is a flow chart of a conformal manufacture method for 3D printing with high-viscosity material disclosed by the present disclosure.

(4) FIG. 3 is a sectional view of a serrate component, a gap and a support disclosed by the present disclosure.

(5) FIG. 4 is a picture of a zirconia ceramic denture having a complex occlusal surface disclosed by Embodiment 3 of the present disclosure.

DESCRIPTION OF THE EMBODIMENTS

(6) The following clearly and completely describes the technical solutions in the embodiments of the present disclosure with reference to the accompanying drawings in the embodiments of the present disclosure. Apparently, the described embodiments are merely a part rather than all of the embodiments of the present disclosure. All other embodiments obtained by a person of ordinary skill in the art based on the embodiments of the present disclosure without creative efforts shall fall within the protection scope of the present disclosure. All other embodiments obtained by a person of ordinary skill in the art based on the embodiments of the present disclosure without creative efforts shall fall within the protection scope of the present disclosure.

(7) Specific embodiments of the present disclosure will be further described in detail with reference to the accompanying drawings.

(8) As shown in FIG. 2, a conformal manufacture method for 3D printing with high-viscosity material comprises the following steps:

(9) S101, using 3D design software to design a 3D model of a component and a conformal contactless support to obtain 3D model data of the component and the conformal contactless support, wherein a gap with a certain thickness is arranged between the support and the component, and an upper surface of the support and a lower surface of the component are consistent morphologically;

(10) S102, importing the obtained 3D model data of the component and the conformal contactless support into slice software to obtain multiple slice data of the component and the conformal contactless support;

(11) S103, importing the multiple slice data of the component and the conformal contactless support into a 3D printing device, and sequentially scanning a high-viscosity material by laser till completing the printing so as to obtain a component and a support, wherein the component and the support are solid under laser irradiation, and the gap is not irradiated by the laser so as to maintain original shape and properties of the high-viscosity material; and

(12) S104, removing the support and the uncured materials to finally obtain the component.

(13) It should be noted that, when the 3D model of the support is designed, the shape and size of the support can be adjusted according to the morphology of the bottom surface of a component to be printed and is subject to conditions that consumables of a conformal contactless support are the least and a component at an upper portion is sufficiently supported.

(14) The high-viscosity material is a photosensitive material, its viscosity range is between 1000 cps and 1000000 cps, and the high-viscosity material may also be pasty ceramic or resin material, but is not limited thereto.

(15) The size of the gap is 1-100 times of the thickness of a slice of the component in order that the support can be easily peeled off and does not damage the surface of the component. A printing material in the gap can be achieved in any mode of extruding, scraping or spraying, but is not limited thereto.

(16) Printing parameters of the support and the component are the same or different according to different printing requirements of the component such that high printing efficiency can be achieved.

(17) According to the above method, the component is not collapsed by utilizing its own supportability of the high-viscosity material and the paved gap, and the high-viscosity material cannot be scraped away during transverse coating due to characteristics of the high-viscosity material; due to the high-viscosity material in the gap, the component and the support can be easily separated and the surface of the component is not damaged; and as shown in FIG. 3, which is a sectional view of a serrate component 1, a gap 2 and a support 3, during printing and after transverse coating, laser scanning is performed according to the slice data, laser is closed when there is no slice data, and this cycle repeats until the printing of the whole serrate component 1 is completed.

Embodiment 1

(18) Steps of manufacturing a component having a complex bottom surface structure with a high-viscosity photosensitive resin material are: firstly performing a 3D model design and slice on a plastic component and support to be printed, secondly importing slice data of the plastic component and the support into a light curing 3D printer, sequentially irradiating slice layers of the plastic component and a base support to form solid component and base support, shutting the laser, coating the photosensitive resin material on a conformal contactless gap by a coating device in order that at least one layer maintains original properties of the photosensitive resin material, and finally removing the uncured material in the conformal contactless gap and the base support, thereby obtaining the plastic component having the complex bottom surface structure. Main printing parameters are: a light source is 355 nm, a power is 300 mw, a laser scanning speed of the component is 4000 mm/s, a laser scanning speed of the base support is 2000 mm/s, the size of the gap is 0.3 mm, and the thickness of a slice is 0.1 mm.

Embodiment 2

(19) Steps of manufacturing an alumina ceramic component having a complex bottom surface structure with alumina paste having a high viscosity characteristic are: firstly performing a 3D model design, a conformal contactless gap and a base support to be sliced, secondly importing slice data into a ceramic 3D printer, sequentially scanning the alumina paste to form a solid alumina ceramic component and support, circularly coating a gap by using a scraping mechanism when the laser is shut till the printing of the whole component is completed, then removing the support, debinding and sintering to finally obtain the alumina ceramic component. Main printing parameters are: a light source is 355 nm, a power is 300 mw, a scanning speed of the ceramic component and a scanning speed of the base are 4000 mm/s, the size of the gap is 0.21 mm, and the thickness of a slice is 0.07 mm. Main debinding and sintering parameters are: the temperature is increased from the room temperature to 120 degrees centigrade for 4 h and is maintained for 5 h; the temperature is increased from 120 degrees centigrade to 600 degrees centigrade for 16 h and is maintained for 2 h; the temperature is increased from 600 degrees centigrade to 1580 degrees centigrade for 3.26 h and is maintained for 2 h; and the temperature is cooled to the room temperature with the furnace.

Embodiment 3

(20) As shown in FIG. 4, steps of manufacturing a zirconia ceramic denture having a complex occlusal surface by using a high-viscosity zirconia photosensitive material are: firstly performing a 3D model design of a ceramic denture and a conformal contactless gap and a support to be printed, secondly importing slice data into a ceramic 3D printer, sequentially scanning zirconia paste by using laser to form a solid ceramic denture component and support, circularly coating a gap by using a scraping mechanism when the laser is shut till the printing of the whole component is completed, then removing the support to obtain the zirconia ceramic denture green body with high surface quality, debinding and sintering to finally obtain the zirconia ceramic denture. Main printing parameters are: a light source is 355 nm, a power is 600 mw, a scanning speed of the zirconia ceramic denture is 1000 mm/s, a scanning speed of a base support is 4000 mm/s, the size of the gap is 0.12 mm, and the thickness of a slice is 0.04 mm. Main debinding and sintering parameters are: the temperature is increased from the room temperature to 75 degrees centigrade for 4 h and is maintained for 6 h; the temperature is increased from 75 degrees centigrade to 170 degrees centigrade for 6 h and is maintained for 8 h; the temperature is increased from 170 degrees centigrade to 330 degrees centigrade for 20 h and is maintained for 6 h; the temperature is increased from 330 degrees centigrade to 500 degrees centigrade for 14 h; the temperature is increased from 500 degrees centigrade to 1250 degrees centigrade for 7.5 h; the temperature is increased from 1250 degrees centigrade to 1450 degrees centigrade for 1 h and is maintained for 2 h; and the temperature is cooled from 1450 degrees centigrade to the room temperature for 36 h.

(21) The above component is not in contact with the support, and due to the gap having the original characteristics of the high-viscosity material, the component and the support are very easy to be peeled off, and no trace is left on the surface of the component.

(22) The foregoing descriptions is merely preferred embodiments of the disclosure, it should be noted that various modifications and variations can be made by those ordinarily skilled in the art without departing from the creation and conception of the present disclosure and are within the scope of the present disclosure.