EQUIPMENT AND METHOD FOR ADDITIVE MANUFACTURING
20200102529 · 2020-04-02
Inventors
- Fabien Guillemot (Preignac, FR)
- Bertrand Viellerobe (Merignac, FR)
- Jérôme Bouter (Bordeaux, FR)
- Evarzeg Le Bouffant (Merignac, FR)
- Romain Voucelle (Bordeaux, FR)
- Dan Soto (Bordeaux, FR)
Cpc classification
B33Y10/00
PERFORMING OPERATIONS; TRANSPORTING
B29C64/112
PERFORMING OPERATIONS; TRANSPORTING
B33Y80/00
PERFORMING OPERATIONS; TRANSPORTING
B33Y40/00
PERFORMING OPERATIONS; TRANSPORTING
C12M21/08
CHEMISTRY; METALLURGY
B41J2/435
PERFORMING OPERATIONS; TRANSPORTING
B41J2/14104
PERFORMING OPERATIONS; TRANSPORTING
International classification
C12M3/00
CHEMISTRY; METALLURGY
B33Y10/00
PERFORMING OPERATIONS; TRANSPORTING
B33Y30/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The present disclosure relates to equipment and a method for additive manufacturing, comprising an orientable energy excitation means for generating intermittent interaction with a fluid covering a blade in order to trigger a jet oriented in the direction of a target, the fluid consisting of a liquid vector containing inhomogeneities, wherein: the fluid forms a liquid film of a thickness measuring less than 500 m on a blade having at least one area allowing the interaction with the laser, into which at least one inlet leads, the interaction area leading into at least one outlet, the equipment also comprising means for the circulation of the fluid between the inlet and the outlet.
Claims
1. An additive printing apparatus, comprising: a slide having at least one zone allowing interaction between a fluid film on the slide and an energy beam, a fluid inlet allowing fluid flow into the at least one zone, and a fluid outlet allowing fluid to flow out from the at least one zone; an orientable energy excitation device for producing a point of interaction between an energy beam emitted by the energy excitation device and a fluid film on the slide to cause a jet oriented toward a target, the fluid comprising a liquid containing transferable inhomogeneities; and a fluid circulation system configured to circulate fluid between the inlet and the outlet, wherein the slide and the fluid circulation system are configured to form a fluid film having a thickness of less than 500 m on the at least one zone of the slide.
2. The apparatus of claim 1, wherein the slide and the fluid circulation system are configured to form a fluid film having a thickness of between 20 and 100 m.
3. The apparatus of claim 1, wherein the slide and the fluid circulation system are configured to form a fluid film having a thickness that is between 3 and 10 times a nominal size of the transferable inhomogeneities.
4. The apparatus of claim 1, wherein the at least one zone of the slide has an area greater than 0.05 mm.sup.2.
5. The apparatus of claim 1, wherein the fluid inlet opens into a lateral part of the at least one zone of the slide.
6. The apparatus of claim 1, wherein the at least one zone of the slide-has a peripheral part opening laterally into the fluid outlet.
7. The apparatus of claim 1, wherein the fluid inlet and the fluid outlet comprise tubular channels.
8. The apparatus of claim 1, wherein the fluid circulation system includes a controller for controlling a flow rate of the fluid of the fluid film on the at least one zone of the slide.
9. The apparatus of claim 8, wherein the fluid circulation system further includes a sensor for measuring the thickness of the fluid film, and where in the controller is configured to control the thickness of the fluid film in the at least one zone of the slide.
10. The apparatus of claim 1, wherein the at least one zone of the slide comprises a plurality of zones, each zone of the plurality further comprising a fluid inlet and a fluid outlet.
11. The apparatus of claim 10, wherein at least two zones of the plurality of zones have common fluid inlets and/or fluid outlets.
12. The apparatus of claim 1, wherein the energy excitation device comprises a laser.
13. The apparatus of claim 12, wherein the at least one zone of the slide is transparent to wavelengths of the laser, and does not have any sacrificial layer.
14. The apparatus of claim 13, wherein the fluid of the fluid film comprises an absorbent pigment in an emission wavelength of the laser.
15. The apparatus of claim 12, further comprising an imaging system configured to acquire images of the at least one zone of the slide.
16. The apparatus of claim 12, wherein the laser emits pulses in picosecond or femtosecond mode with an energy level between 20 and 40 microjoules, the energy level per pulse being controlled by a computer according to a result of a measurement of fluid characteristics present in the at least one zone of the slide, the measurements including density in inhomogeneities, and/or viscosity, and/or film thickness.
17. The apparatus of claim 12, wherein the laser emits pulses in nanosecond mode with an energy of 0.5 to 20 millijoules, the energy level per pulse being controlled by a computer according to a result of a measurement of fluid characteristics present in the interaction zone, the measurements including inhomogeneity density, and/or viscosity, and/or film thickness.
18. The apparatus of claim 1, wherein the energy excitation device comprises an acoustic wave generator.
19. The apparatus of claim 1, wherein the energy excitation comprises a surface wave generator configured to generate vibrations.
20. The apparatus of claim 1, further comprising an imaging system configured to acquire images of the at least one zone of the slide.
21. The apparatus of claim 1, wherein the slide comprises a mesa-shaped plate, an upper surface of which defines the at least one zone of the slide, the slide having on either side of the plate a transverse groove, each of the grooves communicating through a hole with a duct respectively vertically traversing the slide and opening into the corresponding groove respectively.
22. (canceled)
23. (canceled)
24. A method of additive printing, comprising: providing a slide having at least one zone allowing interaction between a fluid film on the slide and an energy beam, a fluid inlet allowing fluid flow into the at least one zone, and a fluid outlet allowing fluid to flow out from the at least one zone; providing an orientable energy excitation device for producing a point of interaction between an energy beam emitted by the energy excitation device and a fluid film on the slide in the at least one zone to cause a jet oriented toward a target, the fluid comprising a liquid containing transferable inhomogeneities; and circulating fluid between the inlet and the outlet of the slide and forming the fluid film on the slide, the fluid film having a thickness of less than 500 m on the at least one zone of the slide.
25. The method of claim 24, wherein the energy excitation device comprises a laser configured to generate a pulsed laser beam, the method further comprising: measuring characteristics of the fluid film in the at least one zone of the slide, the measurements including particle density, and/or viscosity, and/or film thickness; and controlling an energy level per pulse of the pulsed laser beam using a computer as a function of the measured characteristics of the fluid film in the at least one zone of the slide.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0063] The present disclosure will be best understood upon reading the following detailed description of a non-limiting exemplary embodiment, while referring to the appended drawings, wherein:
[0064]
[0065]
[0066]
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[0068]
[0069]
[0070]
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[0075]
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[0077]
[0078]
DETAILED DESCRIPTION
[0079]
[0080] A slide (2) made of glass or transparent material defines a cavity (3) in which flows a carrier fluid (4) containing transferable particles (5).
[0081] The depth of this cavity is less than 500 m and preferably from 50 to 100 m thick, thus avoiding settling phenomena in the cavity (3).
[0082] This cavity (3) is formed by molding, machining, blowing (glass) or 3D printing (FDM, SLS, SLA, DLP, DMLS, EBM, CLIP, MultiJet, etc.) and has a circular, or rectangular, or oval, section, or other geometric shapes. Its transverse surface (6) defines a working area that can be scanned by the laser beam (1) and visualized on a sensor via an optical retrobeam.
[0083] The carrier fluid (4), pushed by a pumping system (15), enters the cavity (3) through an inlet (7) connected to a supply duct (8) itself connected to a supply tank (14), and is discharged via an outlet (9) to a discharge and/or exhaust duct (10).
[0084] The discharge and/or exhaust duct (10) leads to a recovery tank (13) containing the carrier fluid (4) loaded with transferable particles (5). A pumping system (15) circulates the carrier fluid (4) loaded with transferable particles (5). The supply tank (14) and the recovery tank (13) can be separated or form a single tank if the same fluid is to be recirculated in the system several times. In this configuration, the interest is to maximize the number of particles printed in the circulating fluid.
[0085] Optionally, the system includes several sets of supply tanks (14 and 13), each containing a carrier fluid loaded with inhomogeneities of different kinds. A valve is used to select one of the tanks, to allow the deposition of particles of different kinds and the formation of differentiated layers on the target (11).
[0086] The flow rate of the carrier fluid (4) is adjusted to ensure that the working area of the transferable particles (5) is moved at a speed that allows selection by appropriate means (imaging, spectroscopy, etc.) and activates those selected by a laser pulse.
[0087] The target (11) is movable in a plane X, Y parallel to the transverse surface (6) of the cavity (3) to determine the deposition point of the transferred particle (12) and optionally in a perpendicular direction, to adjust the distance travelled by the transferable particle (5) to be transferred. In this case, it is possible to modulate the size of the droplets deposited on the printing substrate.
[0088]
[0089] This optical system consists of two angularly oscillating mirrors (galvanometer type) (20), allowing to scan the laser shooting area, and a first optical unit (21) consisting of a scanning lens, of F-Theta type, allowing to form a laser spot whose diameter on the working plane is the smallest and most constant possible. This first optical unit (21) is made up in a known way by a system of several lenses.
[0090] Upstream of the scanning mirrors (20), the optical system includes a laser source (22) whose beam is reflected back to the scanning mirrors (20) by a dichroic mirror (23).
[0091] A second optical unit (24) forms an image of the working area (25) using the retro-beam passing through the dichroic mirror (23), on a sensor (26).
[0092]
[0093] It consists of three circuits consisting of three parallel cavities (30, 31, 32), each extending between a supply duct (33 to 35 respectively) and an exhaust duct (36 to 38 respectively).
[0094] Each circuit ensures the circulation of a carrier fluid containing transferable inhomogeneities (39 to 41) of potentially different natures. Indeed, either they are of the same nature that could allow larger fields in size to be printed or the printing process to be accelerated (gain in productivity), or they are of a different nature that could make it possible to manufacture complex and customized items (gain on the range of manufacturable items), it is the multicolor aspect provided by this type of architecture.
[0095] To select one of the cavities, the slide (2) can be mechanically moved in a direction perpendicular to the main axis of the three cavities, or the scanning of the laser beam can be made to cover the entire slide (2).
[0096]
[0097]
[0098]
[0099] The combination of ducts and lamellae ensures that the fluid (4) is properly directed onto the slide (2). Images proving that thin films are possible are shown in photographs 6.j, 6.k and 6.l obtained by imaging (camera and image recovery lens) across the equipment. Depending on the pressure parameters of the fluid (4) at the inlet (7) and the suction of the fluid (4) at the outlet, it is possible to modulate the central thickness of the film. For example, thicknesses of 136 m, 100 m and 56 m were obtained experimentally and are illustrated in
[0100] The monitoring of these thicknesses correlated to the adaptation of the laser excitation parameters (energy, focusing, etc.) allows the fine adjustment of the jets generated by the laser absorption. The upper shape of the film is not necessarily flat as can be seen in the photographs. This depends on the parameters of the fluid (4) (viscosity, density, flow rate . . . ) and the pressure/suction parameters of the fluid. The laser shooting area can be spatially adapted to a part of the film where the thickness is constant. This zone can also correspond to the entire cavity, but in this case, the laser parameters will be adapted to the variations in film thickness in the target field.
[0101] The characterization of the film could also be carried out by other means than the imaging mentioned here, such as spectroscopic analysis, distance measurement, line shadowgraph, etc.
[0102]
[0107] The examples cited here are therefore not limiting to the architectures that the equipment according to the present disclosure could have.
Detailed Description of the Printing Method without Sacrificial Layer According to the Present Disclosure
[0108]
[0109] The first step involves focusing the laser on the material, which in this case is the ink arranged in the form of a film (4) in the cavity (3). The way the laser is focused directly impacts the volume that will absorb the deposited energy. This is called laser fluence (energy in relation to surface or volume). As the method does not use a sacrificial layer, it is the ink and most of its liquid medium that absorbs the laser energy. In fact, the choice of laser wavelength and energy has a direct impact on the absorption capacity of the film (4).
[0110] In the case of bio-printing, the ink is essentially composed of water that has well-known absorption peaks at the spectral level. It will therefore be possible to try to maximize this absorption by choosing laser sources corresponding to these maxima (e.g., infra-red water absorption lines). It may also be possible to try to maximize absorption through absorbers placed in the ink (molecules, dyes, particles). In the examples illustrated in the present disclosure, the laser used works at 1030 nm wavelength (ytterbium) for a pulse duration covering a range from 10 picoseconds to 400 femtoseconds and energies between 1 and 40 Joules. Preferably, a laser with a pulse duration of 10 picoseconds for an energy per pulse of 10 to 14 Joules was used.
[0111] The second step corresponds to the creation of the plasma (81), which is the result of the dissociation of the material following the absorption of the laser beam by the film fluid (4). This plasma is made up of a mixture of atoms, ions, electrons, molecular residues, etc.
[0112] The plasma is created over extremely short times, typically a few picoseconds after laser absorption and has a very short life time on the order of one microsecond. The size of the plasma (81), its spatio-temporal dynamics, its temperature, and its components are very strongly related to the duration of the laser pulse used. If the latter is in a so-called short regime from the microsecond to the nanosecond, the main effects at the origin of plasma are linear absorption effects with local temperature increases on the order of one to a few degrees. It is a thermal process. It is considered to be more coarse on the quality of plasma containment in a well-controlled and small space. On the other hand, if the pulse duration is in a so-called ultra-shortregime, i.e., corresponding to pulse durations of a few tens of picoseconds to one femtosecond, then the effects at the origin of the plasma will be a combination of linear and non-linear effects.
[0113] Moreover, the shorter the pulse duration, the more non-linear effects will be favored. The advantage of using these regimes lies in the access to so-called athermal processes to ensure plasma containment in a very well bounded and very small space without temperature rise. This regime is therefore more favorable to cell viability a priori as well as to high resolution. In the case of the present disclosure, the main results were obtained between 5 and 10 picoseconds, a regime that mixes both linear and non-linear effects. They demonstrated the ability to print both homogeneous and colloidal media without sacrificial layers.
[0114] The third step is to create the cavitation bubble (82) in the medium. This bubble is the result of the recombination of the plasma components into a pressurized gas. Recombination is based on many complex physical processes such as field effects, radiative and non-radiative recombinations, tunnel effects, etc. . . . . Cavitation is very strongly dependent on the size and quality of the initial plasma (81). Cavitation bubble (82) appears after about one microsecond following absorption by the laser and the creation of the plasma. It can have a spherical shape but can also have an elongated or annular shape. It all depends on the initial plasma and its shape. The polarization of the laser and the geometric distribution of its energy at the focal plane have a direct influence on the shape of the plasma and therefore on the shape of the cavitation bubble. Thus, to obtain more reproducible results, isotropic forms, such as circular laser polarization, will be preferred.
[0115] Lastly, the fourth step corresponds to the so-called hydrodynamic phase where the cavitation bubble (82) will grow, deform, cause liquid movements, etc. The different phases of these hydrodynamic phenomena are already partly known through certain theories such as those of Pearson or Wortington, etc. The final result is the creation of a material jet (83) at the free surface of the liquid. The surface tension of the liquid, the distance from the bubble to the free surface, the viscosity of the liquid are among the most influential parameters on the shape and dynamics of this jet (83).
[0116] Thus, printing without a sacrificial layer will depend on a very large number of parameters related to both the laser and the ink used. The control of the ink film by the described equipment according to the present disclosure is a means of regulating some of the possible disparities (sedimentation, drying, variable and uncontrolled thickness, . . . ) during printing. In addition, the possibilities of modulating the flow rate and thickness of the film by means of pressure and suction could make it possible to modulate the size, shape and dynamics of the jets. Thus, with such a disclosure, it becomes possible to reduce the range of laser parameters required to modulate the jets. The direct impact of such a choice would be to use a laser that is much simpler in its definition, more stable and above all much less expensive because it is less versatile.
[0117]
[0118] The following
[0123] Thus,
[0124]
[0125]
[0126]
[0127] Lastly,
[0128]
[0129] The slide has a transverse groove (110, 120) on either side of this plate (100).
[0130] Each of the grooves (110, 120) communicates through a hole (111, 121) with a respective duct (112, 122) vertically passing through the slide (2) and opening into the corresponding groove respectively (110, 120).
[0131] The flow of the fluid occurs in a direction represented by the axis (105) corresponding to the longitudinal direction, between a first transverse groove (110) and a second transverse groove (120).
[0132] The first groove (110) is normally used for fluid supply, which passes through the plate (100) before flowing into the second groove (120) where the fluid is then sucked up. However, it is also possible to change the flow direction temporarily, so as to ensure an alternating flow at the surface of the plate (100).
[0133] Tubes (113, 123) are connected respectively to the hole (111, 121) for the supply and/or suction of fluid carrying the transferable particles. One of the ducts can be connected by a multi-way valve to several inlets (114 to 116) of fluids of different types. Each of these channels can work either in flow rate (such as syringe pump) or pressure
[0134] The other two edges of the plate (100), not adjacent to the grooves (110, 120), are optionally bordered by a flange (130, 140) to form a delimited fluid flow area. Similarly, the outer lateral edges of the slide are delimited by walls (150, 160).
[0135] The control of the supply and/or suction flow rate makes it possible to control the flow to ensure a homogeneous distribution of the liquid over the open part of the print head.
[0136] A first solution is to provide an inlet port and a rectangular outlet, the inlet and outlet ports being defined by the upper surface of the transverse grooves (110, 120) as shown in
[0137] The lateral edges (130, 140) ensure that the shape of the liquid meniscus in the plane containing the axis (105) can be controlled. They can be physical or chemical.
[0138] According to a particular embodiment of the present disclosure, the liquid film has a perfectly flat or thinner thickness at the edges so that the flow has a higher hydrodynamic resistance at the edges.
[0139] This solution may also include: [0140] different elements to be able to control the thickness of the liquid; [0141] walls (150, 160) upstream and downstream on which inking of the contact lines is facilitated; and [0142] a central plate (100) for raising the film to reduce the thickness of the film in the interaction area.
[0143] Another solution to alternate the nature of the fluid is to alternate between a fluid containing transferable particles and an inert liquid.
[0144] Another solution consists of a liquid discharge pipe with at least two channels.
[0145] The operation is then as follows: [0146] Step 1 of initialization: [0147] In order to create a liquid bridge on the print head connecting the injection point and the discharge point, a control process is set up. [0148] A first solution is to inject liquid from the cartridges to the head from the injection and discharge point. [0149] Another solution is to inject liquid from the cartridge to the head only from the injection point. [0150] Another solution is to use a texture that allows the open part of the print head to be completely wetted. [0151] Automation step 2: [0152] Once the liquid bridge is created, the film thickness is controlled by removing liquid either from the injection point or from the discharge point. [0153] A first example of embodiment establishes a continuous flow and controls the thickness of the film by imposing a flow rate between the injection point and the discharge point. [0154] Another example of embodiment establishes a continuous flow and controls the thickness of the film by imposing a pressure difference between the injection point and the discharge point. [0155] Another example of embodiment operates in batch mode: [0156] injection of an imposed volume from the injection point; and [0157] then adjusting the desired thickness by removing liquid from the injection or discharge point.
[0158] This operation is repeated cyclically.
[0159] In order to better control the liquid film on the print head, sensors can be integrated.
[0160] An example of embodiment uses a confocal system to measure the thickness of the film. Another example of embodiment uses an optical detection system on the injection and discharge ducts. An advantageous development makes it possible to detect the passage of bubbles, particularly on the escape route. An advantageous development makes it possible to detect concentrations, particularly on the injection route.