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WO2018059348A1 - 一种熔融沉积成型的金属三维打印机及其打印方法 - Google Patents

一种熔融沉积成型的金属三维打印机及其打印方法 Download PDF

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Publication number
WO2018059348A1
WO2018059348A1 PCT/CN2017/103153 CN2017103153W WO2018059348A1 WO 2018059348 A1 WO2018059348 A1 WO 2018059348A1 CN 2017103153 W CN2017103153 W CN 2017103153W WO 2018059348 A1 WO2018059348 A1 WO 2018059348A1
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WO
WIPO (PCT)
Prior art keywords
cleaning device
print head
metal
moving motor
dimensional printer
Prior art date
Legal status (The legal status 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 status listed.)
Ceased
Application number
PCT/CN2017/103153
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English (en)
French (fr)
Inventor
苏健强
宋道权
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Print Rite Unicorn Image Products Co Ltd
Original Assignee
Print Rite Unicorn Image Products Co Ltd
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
Application filed by Print Rite Unicorn Image Products Co Ltd filed Critical Print Rite Unicorn Image Products Co Ltd
Publication of WO2018059348A1 publication Critical patent/WO2018059348A1/zh
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/20—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by extruding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/118—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/35—Cleaning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor

Definitions

  • the present invention relates to the field of metal three-dimensional printing, and more particularly to a fused deposition metal three-dimensional printer and a printing method thereof.
  • the present invention is based on a Chinese invention patent application filed on Sep. 30, 2016, the application number of which is incorporated herein by reference.
  • a 3D printer also known as a three-dimensional printer, is a machine that utilizes rapid prototyping technology. Based on a digital model file, a three-dimensional entity is constructed by layer-by-layer printing using a molding material. Before printing, it needs to be modeled by computer modeling software, and then the partitioned 3D model is “partitioned” into a layer-by-layer section, that is, a slice, to guide the 3D printer to print layer by layer.
  • 3D printers have been widely used in the product manufacturing industry. The 3D printer works in the same way as traditional printers. It consists of control components, mechanical components, print heads, consumables (ie molding materials) and media. The printing principle is basically similar. .
  • FDM fused deposition molding
  • SLM laser sintering
  • a first object of the present invention is to provide a metal three-dimensional printer that employs a fused deposition molding method and has the capability of self-cleaning the print head.
  • a second object of the present invention is to provide a printing method of a metal three-dimensional printer which employs a fused deposition molding method and has a self-cleaning print head capability.
  • a third object of the present invention is to provide a smelting deposition molding method and having the capability of self-cleaning print head The printing method of the metal 3D printer.
  • the present invention provides a fused deposition molded metal three-dimensional printer comprising a print head, a molding base, a moving motor assembly, a wire feeding motor and a cleaning device, and a printing head for extrusion Molding material, molding material including metal material and binder, molding seat for carrying molding material, moving motor assembly including X-axis moving motor, Y-axis moving motor part and Z-axis moving motor, X-axis moving motor for driving print head Movement in the X-axis direction; Y-axis moving motor is used to drive the movement of the print head in the Y-axis direction, Z-axis moving motor is used to drive the movement of the forming block in the Z-axis direction, and the wire feeding motor is used for conveying the wire
  • the molding material is placed in the print head, the cleaning device and the print head are disposed on the same horizontal surface, the cleaning device is located at the outer circumference of the molding seat, and the printing head is adjacent to the cleaning device.
  • the cleaning device is disposed in a scraper shape.
  • a still further solution is that the cleaning device is arranged in a vertical direction.
  • the cleaning device is arranged in a horizontal direction.
  • the mobile motor assembly further includes a horizontal moving motor for driving the cleaning device to move on a horizontal plane.
  • the metal three-dimensional printer further includes a box body enclosing a sealed cavity for loading the print head, the molding base, the moving motor assembly, the wire feeding motor, and the cleaning device.
  • the cleaning device is made of a silicone material.
  • the cleaning device is made of a sponge material.
  • the present invention provides a printing method of a fused deposition molded metal three-dimensional printer including a print head, a molding base, a moving motor assembly, a wire feeding motor, and a cleaning device, and printing
  • the head is used for extrusion molding materials
  • the molding materials include metal materials and binders
  • the molding base is used to carry molding materials
  • the moving motor components include X-axis moving motors, Y-axis moving motor parts, and Z-axis moving motors, and X-axis moving motors.
  • the wire supply The motor is used for conveying the filament-shaped molding material into the print head, and the cleaning device and the print head are disposed on the same horizontal surface, and the printing method comprises: the printing head extrudes the material on the molding seat; the printing head moves to the cleaning device and the cleaning device Adjacent; the print head is separated from the cleaning device.
  • the present invention provides a printing method of a fused deposition molded metal three-dimensional printer, characterized in that the metal three-dimensional printer comprises a print head, a molding base, a moving motor assembly, a wire feeding motor, and Cleaning device, print head for extrusion molding materials, molding materials including metal materials and adhesives, molding base for carrying molding materials, moving motor components including X-axis moving motor, Y-axis moving motor parts, Z-axis moving motor and Moving the motor horizontally, the X-axis moving motor is used to drive the movement of the print head in the X-axis direction; the Y-axis moving motor is used to drive the movement of the print head in the Y-axis direction, and the z-axis moving motor is used to drive the forming block in the z-axis In the direction of movement, the wire feeding motor is used for conveying the filament-shaped molding material into the printing head, the cleaning device and the printing head are disposed on the same horizontal surface,
  • the fused deposition metal three-dimensional printer and the printing method thereof adopt the principle of extrusion imaging of a print head, and the molding material comprises a metal material and a binder, and the three-dimensional printing is performed by using FDM molding method, and the molding efficiency thereof is high.
  • the cost is low, and the molten material has a metal material forming material. Due to the metal material, and after being ejected from the print head, the molten wire is deformed and retracted by the internal stress due to the low ambient temperature. The molten wire at the spout of the head is easy to adhere around the spout, and there is also a situation that the residual material flows out from the nozzle position.
  • the cleaning device is used to clean the print head after completing one layer printing, and the specific method can be actively moved and cleaned by using the print head, or The cleaning device actively moves and cleans, so that the cleaning device wipes or cleans the excess molten molding material, and then performs the next layer of printing, thereby improving the image quality.
  • the cleaning device provided in the squeegee can cleanly and quickly, while the vertical arrangement or the horizontal arrangement can be arranged with different material properties of different materials, which can bring different wiping effects, and the same can be
  • the print head is cleaned by means of a cleaning device actively walking and wiping.
  • the heat-insulated sealed chamber can reduce heat loss during heating, contribute to the existence of internal stress of the three-dimensional object, and increase the strength between the layers, and prevent metal oxidation.
  • the temperature is high, it is necessary to perform wiping cleaning using a silica gel or a sponge having high temperature resistance, which can further improve the cleanliness.
  • FIG. 1 is a partial structural schematic view of an embodiment of a metal three-dimensional printer of the present invention.
  • FIG. 2 is a schematic view showing the cleaning principle of the embodiment of the metal three-dimensional printer of the present invention.
  • FIG. 3 is a flow chart of an embodiment of a method of manufacturing a three-dimensional shaped wire according to the present invention.
  • FIG. 4 is a structural view of a screw extruder and a molding extruder head of an embodiment of a method for producing a three-dimensionally shaped yarn of the present invention.
  • FIG. 5 is a schematic illustration of the filamentous material of the three-dimensional shaped filament embodiment in a linear state and a curved state.
  • FIG. 6 is a graph of three-dimensionally forming part of the components of the seventh to eleventh embodiments.
  • FIG. 1 is a partial structural view of a metal three-dimensional printer 1.
  • the three-dimensional printer 1 includes a casing 11 which can adopt a rectangular parallelepiped casing composed of six faces.
  • the casing 11 encloses a closed cavity for three-dimensional imaging, in which an X-axis moving motor 21 and a Y-axis movement are mounted.
  • the motor 22 and the Z-axis moving motor 23, the Z-axis moving motor 23 are mounted at the bottom of the cavity, and the screw is connected to the Z-axis moving motor 23, and a guide rod is further mounted on the bottom wall of the cavity, and the guide bar is mounted thereon.
  • the Z-axis moving bracket is provided with a forming seat 12 on the Z-axis moving bracket. Since the Z-axis moving bracket meshes with the screw thread, when the Z-axis moving motor 23 works, the screw will be driven to rotate, and then the forming seat 12 is in the Z The shaft moving motor 23 is driven to move in the Z-axis direction.
  • the Y-axis moving motor 22 is mounted on the side wall of the cavity, and a guide rod is fixedly disposed on the side wall, a Y-axis moving bracket is disposed on the guiding rod, and the Y-axis moving motor 22 passes through a belt (not shown) ) is connected with the Y-axis moving bracket.
  • a belt (not shown)
  • the Y-axis moving bracket will be slid along the guide rod by the belt, that is, the Y-axis moving bracket is driven by the Y-axis moving motor 22 in the Y-axis direction. mobile.
  • An X-axis moving motor 21 and two guiding rods are mounted on the Y-axis moving bracket, and two guiding rods are respectively disposed on two sides of the X-axis moving motor 21, and the printing head 13 is disposed on the two guiding rods.
  • a feed end is provided at an upper end of the print head, and the feed end is for receiving a filament-shaped molding material, and a discharge port is provided at a lower end of the print head 13, and the discharge port is used for extrusion molding on the molding seat 12. material.
  • the X-axis moving motor 21 is connected to the print head 13 via a belt. When the X-axis moving motor 21 is rotated, the print head 13 is slid along the guide rod by the belt, that is, the print head 13 is driven by the X-axis moving motor 21 at X. Move in the direction of the axis.
  • a consumable supply driving motor, a driving wheel and a driven wheel are mounted on the print head 13, and the driving wheel is connected to the consumable supply driving motor, and the driving wheel and the driven wheel are disposed on both sides of the filament-shaped molding material 15, the driving wheel and The driven wheel is in close contact with the molding material 15.
  • the belt is rotated to the driving wheel, and the molding material 15 is driven to move toward the discharging end by the rotation of the driving wheel.
  • a heating chamber is disposed between the driving wheel and the discharge end. Since the molding material includes a metal material and a binder, the heating chamber heats and melts the molding material 15 entering from the feeding end, so that the binder is in a molten state.
  • the metal material is mixed and sprayed from the discharge end and placed on the molding base.
  • the above-described X-axis moving motor 21, the ⁇ -axis moving motor 22, the ⁇ -axis moving motor 23, and the consumable supply motor are all stepping motors.
  • the metal three-dimensional printer 1 further includes a cleaning device 14 fixed in a casing, the cleaning device 14 is disposed in a scraper shape, and the cleaning device 14 is arranged in a vertical direction, the upper end portion of the cleaning device 14 and the print head 13 is disposed on the same horizontal surface, in order not to affect the normal printing, the cleaning device 4 cannot be disposed in the upper area of the molding seat 12, otherwise the walking of the printing head 13 may be disturbed, so the cleaning device 4 is disposed at the outer periphery of the molding seat 12. on.
  • the print head 13 extrudes a layer of molding material on the molding seat 12, and then the molding seat 12 is moved downward by a predetermined distance, and then the print head 13 is moved to the cleaning device 14 and adjacent to the cleaning device 14, and then printed.
  • the head 13 moves and separates from the cleaning device, and then proceeds to perform imaging of the next layer.
  • the relative movement of the cleaning head 14 by the movement of the print head 13 and the wiping of the molten molding material are achieved.
  • the cleaning device can also be arranged in a horizontal direction, and the material of the cleaning device can also be excellently selected.
  • the cleaning device can be made of high temperature resistant silicone material or high temperature resistant. Made of sponge material.
  • the embodiment can actively clean the cleaning device, specifically, a horizontal moving motor, a guide rod and a belt are arranged in the box body, and the rotating drive and the belt are driven by the horizontal moving motor. Under the action of the transmission and the guide rod, the cleaning device can be moved in the X direction or in the Y direction, and the initial position of the cleaning device is set at the position of the outer circumference of the molding seat.
  • the X-axis moving motor, the Y-axis moving motor member, the Z-axis moving motor, and the horizontal moving motor in the above embodiment constitute the moving motor assembly of the present invention.
  • the print quality, print head, molded base, moving motor assembly, wire feed motor and cleaning device can be placed in a closed box, which in turn reduces heat loss during heating.
  • the printing method includes: first, the print head extrudes the first layer of the molding material on the molding seat, and then the molding seat moves downward by a predetermined distance, and then the cleaning device moves to The print head is adjacent to the print head, and then the cleaning device is separated from the print head, and the cleaning device moves relative to the print head to move the melt molding material, and the print head moves downward by a predetermined distance, so the print head and the print head There is a certain gap between the completed models, so this embodiment uses a horizontally extended cleaning device.
  • the molding material includes a metal material and a binder, and the three-dimensional printing is performed by the FDM molding method, and the molding efficiency is high and the cost is low, and the molten state has a metal material.
  • the molding material due to its metal material, and after being ejected from the print head, due to the low ambient temperature, the molten wire is deformed and retracted by the internal stress, and the molten wire at the nozzle of the print head is easily attached around the nozzle.
  • the cleaning head is used to clean the print head after the completion of one layer printing.
  • the specific method can be actively moved by the print head, or actively cleaned by a cleaning device to wipe the cleaning device. Or clean the excess molten molding material and print the next layer, which in turn improves the image quality.
  • the molding material in the above embodiment can be formed into a three-dimensional forming wire in the present embodiment by wire drawing.
  • the following examples specifically describe how the three-dimensional forming wire is produced and distributed in this case.
  • the three-dimensional forming wire comprises a metal material, a binder, a dispersing agent, a flexibility enhancer And a stabilizer, wherein the metal material accounts for 80% to 93% of the total weight of the three-dimensional shaped silk; the binder accounts for 1% to 10% of the total weight of the three-dimensional shaped silk; the dispersant accounts for three-dimensional shaped wire
  • the total weight percentage of the material is 0.1% to 5%; the total weight percentage of the flexibility enhancer to the three-dimensional shaped silk is 0.1 ⁇ 3 ⁇ 4 to 5 ⁇ 3 ⁇ 4 ; the total weight percentage of the stabilizer to the three-dimensional shaped silk is 0.1% to 1 %.
  • the metal material is Fe/Ni metal material (iron-nickel alloy), Wc/Co/Cu metal material (tungsten carbide/cobalt/copper alloy), YBa 2 Cu 3 0 7 metal material (yttrium copper oxide) SiC metal material (silicon carbide), Si 3 N 4 metal material (silicon nitride), Si/Al metal material (silicon aluminum alloy), Al 2 0 3 /Tic metal material (alumina/titanium carbide composite) ), iron metal materials, cobalt metal materials, molybdenum metal materials, chromium metal materials, base metal materials, nickel metal materials, manganese metal materials, tungsten metal materials, copper metal materials, aluminum metal materials.
  • Fe/Ni metal material iron-nickel alloy
  • Wc/Co/Cu metal material tungsten carbide/cobalt/copper alloy
  • YBa 2 Cu 3 0 7 metal material yttrium copper oxide
  • SiC metal material silicon carbide
  • Si 3 N 4 metal material silicon nitride
  • the binder is a paraffin-based binder, beeswax, stearic acid, carnauba wax, ethylene ethyl acrylate, styrene acrylonitrile (SAN ) resin, acrylonitrile-styrene-butadiene copolymerization (ABS) resin, polybutylene terephthalate (PBT), polyethylene glycol diacrylate, dipropylene glycol, acrylic acid ester, 2-pyrrolidone, polybutylene terephthalate, ethyl Cellulose, acetate, hydroxypropylcellulose, low nitrogen nitrocellulose, ethylene-butene cellulose, polyvinyl butyral, polyethylene terephthalate, polystyrene, nylon.
  • SAN styrene acrylonitrile
  • ABS acrylonitrile-styrene-butadiene copolymerization
  • PBT polybutylene terephthalate
  • PBT poly
  • the dispersing agent is at least one of the following: polyamide (PA), polyoxymethylene (POM)
  • the stabilizer is a zinc oxide-based heat stabilizer.
  • the flexibility enhancer is a mixture of dioctyl phthalate and dibutyl phthalate, and the weight percentage of dioctyl phthalate and dibutyl phthalate is 0.1: 1 to 10: 1.
  • the metal material occupies a weight percentage of 85% to 90%; the binder occupies 4% to 9% by weight; the dispersant occupies 0.5% to 3% by weight; the flexibility enhancer The percentage by weight is 0.5% to 3%; the percentage by weight of the stabilizer is 0.5% to 0.8%.
  • the method of manufacturing the three-dimensional shaped wire of the present embodiment includes the following steps.
  • the preparation step S1 is performed to obtain 80 parts of an iron-nickel alloy (Fe/Ni) metal material, 10 parts of a paraffin-based binder, 0.5 part of a polyamide dispersant, and 0.5 parts of flexibility enhancement. And 0.5 parts of zinc oxide heat stable A fixative.
  • the flexibility enhancer is a mixture of dioctyl phthalate and dibutyl phthalate, and the weight percentage of dioctyl phthalate and dibutyl phthalate is 1:1.
  • the drawing step S3 is performed, and the extruded material is drawn by a wire drawing machine to obtain a filamentous material.
  • the filamentous material 35 may be in the form of a straight line, and is subjected to bending deformation by an external force, and at the same time, the filamentous material 35 does not break after the bending deformation.
  • a cooling step is further included after the drawing step, and the filamentous material is cooled to room temperature in the cooling step.
  • the wire material after drawing is 1.75 mm ⁇ 0.05 mm in diameter.
  • the winding step S4 is performed, and since the filamentous material 35 can be bent and deformed, the filamentous material 35 can be curled on the filament tray.
  • the three-dimensional printer of this embodiment includes a printing platform, a print head, and a three-dimensional forming wire.
  • the print head is movable in a three-dimensional direction with respect to the printing platform, and the three-dimensional forming wire is wound around the wire tray of the FDM three-dimensional printer.
  • the molding method of the three-dimensional printer of this embodiment includes a preliminary molding step and a sintering step, and the three-dimensionally shaped filament is a three-dimensionally formed filament of the present embodiment.
  • the print head melts the three-dimensional shaped wire and forms a preliminary solidified object on the printing platform layer by layer, and the melting temperature of the three-dimensional shaped wire in the print head is 180. C to 350. C.
  • the preliminary solidified object obtained above is placed in a vacuum environment and sintered at a high temperature of 1200 ° C to form a three-dimensional object, and the density of the formed object is 7.70.
  • the specific process of the sintering step can be referred to the process of the existing metal powder sintering process.
  • the method of manufacturing the three-dimensional shaped wire of the present embodiment includes the following steps.
  • the preparation step is performed: obtaining 85 parts of iron-nickel alloy (Fe/Ni) metal material, 10 parts of beeswax bonding ij, 0.3 parts of polyoxymethylene dispersant, 0.7 parts of flexibility enhancer and 0.2 parts of zinc oxide heat stabilizer.
  • soft The toughness enhancer is a mixture of dioctyl phthalate and dibutyl phthalate, and the weight percentage of dioctyl phthalate and dibutyl phthalate is 0.3:1.
  • a wire drawing step is performed, and the extruded material is drawn by a wire drawing machine to obtain a filamentous material, in a preferred embodiment.
  • a cooling step is also included after the drawing step, and the filamentous material is cooled to room temperature during the cooling step.
  • a winding step is performed to crimp the filamentous material onto the wire tray.
  • the three-dimensional printer of this embodiment includes a printing platform, a print head, and a three-dimensional forming wire.
  • the printing head is movable in a three-dimensional direction with respect to the printing platform, and the three-dimensional forming wire is wound around the wire tray of the FDM three-dimensional printer.
  • the molding method of the three-dimensional printer of this embodiment includes a preliminary molding step and a sintering step, and the three-dimensionally shaped filament is a three-dimensionally formed filament of the present embodiment.
  • the print head melts the three-dimensional shaped wire and forms a preliminary solidified object on the printing platform layer by layer, and the melting temperature of the three-dimensional shaped wire in the print head is 200. C to 300. C.
  • the preliminary solidified object obtained above is placed in a vacuum environment and sintered at a high temperature of 1200 ° C to form a three-dimensional object, and the density of the formed object is 7.74.
  • the specific process of the sintering step can be referred to the process of the existing metal powder sintering process.
  • the preparation step 90 parts of iron-nickel alloy (Fe/Ni) metal powder material, 10 parts of beeswax binder, 0.4 parts of polyoxymethylene dispersant, 0.6 parts of flexibility enhancer, and 0.3 parts of zinc oxide heat are obtained. stabilizer.
  • the flexibility enhancer is a mixture of dioctyl phthalate and dibutyl phthalate, and the weight percentage of dioctyl phthalate and dibutyl phthalate is 0.5:1.
  • the preparation step 80 parts of iron-nickel alloy (Fe/Ni) metal powder material, 10 parts of ethylene-propylene were obtained Ethyl acrylate binder, 0.3 parts of polypropylene dispersant, 0.7 parts of flexibility enhancer and 0.2 parts of zinc oxide are thermally stable.
  • the flexibility enhancer is a mixture of dioctyl phthalate and dibutyl phthalate, and the weight percentage of dioctyl phthalate and dibutyl phthalate is 0.3:1.
  • the density of the formed object was 7.75.
  • the preparation step obtaining 85 parts of iron-nickel alloy (Fe/Ni) metal material, 10 parts of stearic acid bonded ij, 0.3 parts of polyoxymethylene dispersant, 0.7 parts of flexibility enhancer and 0.4 parts of oxidation Zinc heat stabilizer.
  • the flexibility enhancer is a mixture of dioctyl phthalate and dibutyl phthalate, and the weight percentage of dioctyl phthalate and dibutyl phthalate is 0.8:1.
  • the density of the formed object is 7.74.
  • the preparation step obtaining 85 parts of iron-nickel alloy (Fe/Ni) metal material, 10 parts of stearic acid bonded ij, 0.3 parts of polyethylene dispersant, 0.7 parts of flexibility enhancer and 0.5 parts of oxidation Zinc heat stabilizer.
  • the flexibility enhancer is a mixture of dioctyl phthalate and dibutyl phthalate, and the weight percentage of dioctyl phthalate and dibutyl phthalate is 1.2:1.
  • the density of the formed object is 7.80.
  • the partial parameter data of the seventh to ninth embodiments of the three-dimensional shaped filament is as shown in FIG. 6.
  • the preparation step obtaining 93 parts of iron-nickel alloy (Fe/Ni) metal material, 6 parts of stearic acid binder, 0.5 part of silicone powder lubricant, 0.5 part of flexibility enhancer and 0.5 part of oxidation Zinc heat stabilizer.
  • the flexibility enhancer is 3. TPE (Thermoplastic Elastomer) material, for example, 3. Styrene elastomer. Since the TPE material is a thermoplastic elastomer material, the use of a TPE material as a flexibility increasing agent can improve the flexibility of the three-dimensional shaped wire.
  • the density of the object after molding in this embodiment was 7.70.
  • TPE materials of different degrees are used, wherein the TPE material of 3° is relatively soft, and the TPE material of 45° is harder than the TPE material of 3°.
  • Fig. 6 shows partial parameters of the tenth embodiment and the eleventh embodiment.
  • Samples were sampled for the three-dimensional shaped wire obtained in the above first to sixth embodiments, and the samples were tested in accordance with the standard GB/T9341-2008.
  • the shape of the sample is: 80.00 mm (mm) long, 10.00 mm (mm) wide, and 4.11 mm (mm) thick.
  • the speed of the sample test was linear speed: 10.0 mm / min (mm / min).
  • the sample test spans 66 mm (mm). The test results of the sample are shown in Figure 7.
  • the bending strength of the three-dimensional shaped wire is greater than 6.9 MPa, thereby achieving bending deformation of the metal-based three-dimensional forming wire without breaking.
  • samples of the three-dimensionally shaped filaments of the eleventh embodiment were sampled, and the samples were tested in accordance with the standard ASTM D790-07.
  • the shape of the sample is: 127.00 mm (mm) long, 12.70 mm (mm) wide, and 3.20 mm (mm) thick.
  • the speed of the sample test was linear speed: 10.0 mm / min (mm / mi n).
  • the test results of the sample are shown in Figure 8.
  • the bending strength of the three-dimensional shaped wire is greater than 36 MPa, thereby achieving bending deformation of the metal-based three-dimensional forming wire without breaking.
  • the three-dimensional shaped filament of the present invention does not comprise a heat stabilizer and is still capable of accomplishing the object of the invention, that is, in the absence of a heat stabilizer, a three-dimensionally shaped filament
  • the bending strength can be achieved and coiled onto the wire tray.
  • the component of the three-dimensional shaped filament further includes a magnetic material such as triiron tetroxide, in the above three-dimensional forming method, in the preparation step and the extrusion step, the magnetic material powder It is added and mixed together with other raw materials such as a binder.
  • the components of the three-dimensional shaped filament may also include a colorant or dye such that the filaments have different colors.
  • the flexibility enhancer is, for example, a plasticizer
  • the plasticizer is, for example, a compound of a phthalate (or a phthalate)
  • the phthalate plasticizer includes: Di(2-ethylhexyl) phthalate (DEHP), di-n-octyl phthalate (DNOP or DnOP), butyl benzyl phthalate (BBP), di-octyl phthalate ( DC P), dicyclohexyl phthalate (DCHP), etc.
  • DEHP Di(2-ethylhexyl) phthalate
  • DNOP or DnOP di-n-octyl phthalate
  • BBP butyl benzyl phthalate
  • DC P di-octyl phthalate
  • DCHP dicyclohexyl phthalate
  • the density between the metal material and the binder is far apart, it is difficult to form a uniform mixing effect, and the addition of the dispersing agent in the component can play a good role in the uniform mixing of the raw materials.
  • the metal material powder and the binder of the present invention form a silk material, since the silk material has a large brittleness, it is likely to be broken at the time of bending, and a flexibility enhancer such as a plasticizer is added to the composition. The flexibility or bending strength is improved, and the above characterization results can be explained.
  • the melting of the three-dimensional forming wire is caused.
  • the temperature has a wide range of fluctuations, for example, the melting temperature ranges from 200 ° C to 230 ° C.
  • the melting temperature of the three-dimensional forming wire can be limited to a small range, for example, 200. °C to 2 05 °C.
  • the present invention is not limited to the above embodiments, such as a bending strength greater than 6.9 MPa.
  • a design having a bending strength of more than 6.5 MPa is also within the scope of the claims of the present invention.
  • the three-dimensional forming wire provided by the present invention contains a large amount of a substrate such as metal or glass, and the metal is used as a substrate, the three-dimensional forming wire of the present invention can be used for a three-dimensional printing process of metal. Moreover, since the flexibility enhancer is added to the yarn, the yarn has good bending strength, the bending of the yarn can be realized, and the yarn can be bent into a disk shape, which is advantageous for the procedure of the yarn.
  • the invention makes the metal material into a flexible metal wire material, and can form a three-dimensional object at a temperature generally set by the FDM three-dimensional printer, thereby greatly improving the forming efficiency of the metal three-dimensional object.
  • This filamentary material allows the bending of the wire-like material, and the bending moment does not break, which is a breakthrough in the application of the FDM three-dimensional printer.
  • the printing of the three-dimensional object by using the silk material of the invention can manufacture the object of the metal material, and the filament material of the invention is applied by using the FDM three-dimensional printer after the forming process of the metal three-dimensional object of the traditional process. Forming, molding efficiency has been significantly improved.
  • the print head is cleaned after the completion of one layer printing by using the above-mentioned proportioning molding material and cleaning device, and the specific method can be actively moved by the print head or actively moved by the cleaning device. Clean, wipe the cleaning device or clean excess molten molding material, Perform the next layer of printing, which in turn improves the image quality.

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Abstract

一种熔融沉积成型的金属三维打印机（1），包括打印头（13）、成型座（12）、移动电机组件、丝料供给电机和清洁装置（14），打印头用于挤出成型材料（15），成型材料包括金属材料和粘结剂，移动电机组件用于驱动打印头和成型座的移动，丝料供给电机用于输送丝状的成型材料至打印头中，清洁装置和打印头设置在同一水平面上，清洁装置位于成型座的外周的位置上，打印头可与清洁装置邻接。以及一种金属三维打印机的打印方法。该金属三维打印机利用清洁装置对打印头去除多余的熔融成型材料，再进行下一层打印，继而提高成像品质，同时采用FDM的成型方式对含有金属材料的成型材料进行金属三维打印，成型效率高且成本低。

Description

一种熔融沉积成型的金属三维打印机及其打印方法 技术领域
[0001] 本发明涉及金属三维打印领域， 尤其涉及一种熔融沉积成型的金属三维打印机 及其打印方法。 本发明是基于申请日为 2016年 9月 30日、 申请号为 CN2016108771 08.8的中国发明专利申请， 上述发明的内容引入本文作为参考。
背景技术
[0002] 3D打印机又称三维打印机， 是一种利用快速成型技术的机器， 以数字模型文件 为基础， 采用成型材料， 通过逐层打印的方式来构造三维的实体。 在打印前， 需要利用计算机建模软件建模， 再将建成的三维模型 "分区 "成逐层的截面， 即切 片， 从而指导 3D打印机逐层打印。 3D打印机在产品制造业获得了广泛的应用， 3 D打印机的工作原理和传统打印机基本相同， 由控制组件、 机械组件、 打印头、 耗材 （即成型材料） 和介质等组成， 打印原理也基本类似。
[0003] 现有的一种常用打印方式是熔融沉积成型 (FDM)， 其是通过在水平移动的打印 头挤出加热熔融后的成型材料， 并在成型座逐层叠堆形成三维模型。 另外一种 打印方式是激光烧结 (SLM)， 其利用粉末激光烧结成型， 基本原理是用粉末铺设 一层后用激光烧结， 然后再用粉末铺设一层， 再激光烧结一次， 循环打印出三 维立体实物。
[0004] 然而上述两种打印方法都存在一定的局限性， 如需要大功率的激光头或者高温 熔化， 才能够实现金属打印， 这就需要三维打印设备非常专业的保护， 而且能 源消耗较多， 成本非常高。
技术问题
[0005] 针对上述的背景技术， 本发明的第一目的是提供一种采用熔融沉积成型方式且 具备自清洁打印头能力的金属三维打印机。
[0006] 本发明的第二目的是提供一种采用熔融沉积成型方式且具备自清洁打印头能力 的金属三维打印机的打印方法。
[0007] 本发明的第三目的是提供一种采用熔融沉积成型方式且具备自清洁打印头能力 的金属三维打印机的打印方法。
[0008] 技术解决手段
[0009] 为了实现本发明的第一目的， 本发明提供一种熔融沉积成型的金属三维打印机 ， 包括打印头、 成型座、 移动电机组件、 丝料供给电机和清洁装置， 打印头用 于挤出成型材料， 成型材料包括金属材料和粘结剂， 成型座用于承载成型材料 ， 移动电机组件包括 X轴移动电机、 Y轴移动电机件和 Z轴移动电机， X轴移动电 机用于驱动打印头在 X轴方向上的移动; Y轴移动电机用于驱动打印头在 Y轴方向 上的移动， Z轴移动电机用于驱动成型座在 Z轴方向上的移动， 丝料供给电机用 于输送丝状的成型材料至打印头中， 清洁装置和打印头设置在同一水平面上， 清洁装置位于成型座的外周的位置上， 打印头可与清洁装置邻接。
[0010] 更进一步的方案是,清洁装置呈刮板状设置。
[0011] 更进一步的方案是,清洁装置沿竖直方向布置。
[0012] 更进一步的方案是,清洁装置沿水平方向布置。
[0013] 更进一步的方案是,移动电机组件还包括水平移动电机， 水平移动电机用于驱动 清洁装置在水平面上移动。
[0014] 更进一步的方案是,金属三维打印机还包括箱体， 箱体围成密闭的腔体， 箱体用 于装载打印头、 成型座、 移动电机组件、 丝料供给电机和清洁装置。
[0015] 更进一步的方案是,清洁装置由硅胶材料制作而成。
[0016] 更进一步的方案是,清洁装置由海绵材料制作而成。
[0017] 为了实现本发明第二目的,本发明提供一种熔融沉积成型的金属三维打印机的 打印方法， 金属三维打印机包括打印头、 成型座、 移动电机组件、 丝料供给电 机和清洁装置， 打印头用于挤出成型材料， 成型材料包括金属材料和粘结剂， 成型座用于承载成型材料， 移动电机组件包括 X轴移动电机、 Y轴移动电机件和 Z轴移动电机， X轴移动电机用于驱动打印头在 X轴方向上的移动; Y轴移动电机 用于驱动打印头在 Y轴方向上的移动， Z轴移动电机用于驱动成型座在 Z轴方向上 的移动， 丝料供给电机用于输送丝状的成型材料至打印头中， 清洁装置和打印 头设置在同一水平面上， 打印方法包括： 打印头在成型座上挤出成型材料； 打 印头移动至清洁装置并与清洁装置邻接； 打印头与清洁装置分离。 [0018] 为了实现本发明第三目的,本发明提供一种熔融沉积成型的金属三维打印机的 打印方法， 其特征在于， 金属三维打印机包括打印头、 成型座、 移动电机组件 、 丝料供给电机和清洁装置， 打印头用于挤出成型材料， 成型材料包括金属材 料和粘结剂， 成型座用于承载成型材料， 移动电机组件包括 X轴移动电机、 Y轴 移动电机件、 Z轴移动电机和水平移动电机， X轴移动电机用于驱动打印头在 X 轴方向上的移动; Y轴移动电机用于驱动打印头在 Y轴方向上的移动， z轴移动电 机用于驱动成型座在 z轴方向上的移动， 丝料供给电机用于输送丝状的成型材料 至打印头中， 清洁装置和打印头设置在同一水平面上， 清洁装置位于成型座的 外周的位置上， 水平移动电机用于驱动清洁装置在水平面上移动， 打印方法包 括： 打印头在成型座上挤出第一层的成型材料； 成型座往下移动预设距离； 清 洁装置移动至打印头处并与打印头邻接； 清洁装置与打印头分离。
问题的解决方案
发明的有益效果
有益效果
[0019] 本发明的熔融沉积成型的金属三维打印机及其打印方法， 采用打印头挤出成像 的原理， 成型材料包括金属材料和粘结剂， 利用 FDM的成型方式进行三维打印 ， 其成型效率高成本低， 而熔融状态的具有金属材料的成型材料， 由于其金属 材料的原因， 而且从打印头喷出后， 由于外界环境温度较低， 溶丝遇冷受到内 应力的作用变形回缩， 打印头的喷口处溶丝容易附着在喷口周围， 还会存在余 料从喷嘴位置流出情况， 利用清洁装置， 在完成一层打印后对打印头进行清洁 ， 具体方式可以采用打印头主动移动清洁， 或采用清洁装置主动移动清洁， 使 清洁装置擦拭或者清洁多余的熔融成型材料， 再进行下一层打印， 继而提高成 像品质。
[0020] 并且， 呈刮板设置的清洁装置能够干净且迅速地进行清洁， 而竖直布置或水平 布置可更加不同材料的不同材料特性进行布置， 其能够带来不同的擦拭效果， 同吋可以采用清洁装置主动行走擦拭的方式对打印头进行清洁。
[0021] 另外， 保温密闭的容纳腔， 可以减少在加热过程中的热量损失， 有助于三维物 体的内部应力存在， 而且增加了层与层之间的强度， 同吋可以防止金属氧化。 [0022] 以及， 由于温度较高， 故需要采用具有耐高温性能的硅胶或海绵进行擦拭清洁 ， 其能够更进一步地提高清洁度。
对附图的简要说明
附图说明
[0023] 图 1是本发明金属三维打印机实施例的局部结构示意图。
[0024] 图 2是本发明金属三维打印机实施例清洁原理示意图。
[0025] 图 3是本发明三维成型丝料的制造方法实施例的流程图。
[0026] 图 4是本发明三维成型丝料的制造方法实施例的螺杆挤出机和成型挤出机头的 结构图。
[0027] 图 5是三维成型丝料实施例的丝状材料处于直线状态和弯曲状态吋的示意图。
[0028] 图 6是三维成型第七至第十一实施例部分组分的图表。
[0029] 图 7是第一至第六实施例实验数据的图表。
[0030] 图 8是第十一实施例实验数据的图表。
[0031] 以下结合附图及实施例对本发明作进一步说明。
具体实施方式
[0032] 金属三维打印机第一实施例：
[0033] 参照图 1， 图 1是金属三维打印机 1的局部结构示意图。 三维打印机 1包括箱体 11 ， 箱体 11可采用 6面组成的长方体箱体， 箱体 11围成用于三维成像的密闭腔体， 在该腔体内安装有 X轴移动电机 21、 Y轴移动电机 22和 Z轴移动电机 23， Z轴移动 电机 23安装在腔体的底部， 在 Z轴移动电机 23上连接有螺杆， 在空腔的底壁还安 装有导杆， 在导杆上安装有 Z轴移动支架， 在该 Z轴移动支架上设置有成型座 12 ， 由于 Z轴移动支架与螺杆螺纹啮合， 所以当 Z轴移动电机 23工作吋， 将带动螺 杆旋转， 继而使得成型座 12在 Z轴移动电机 23的驱动下在 Z轴方向上移动。
[0034] Y轴移动电机 22安装在腔体的侧壁上， 在侧壁上固定设置有导杆， 在导杆上设 置有 Y轴移动支架， Y轴移动电机 22通过一皮带 (未示出)与 Y轴移动支架连接， 当 Y轴移动电机 22转动吋， 将通过皮带带动 Y轴移动支架沿着导杆滑动， 即 Y轴移 动支架在 Y轴移动电机 22的驱动下在 Y轴方向上移动。 [0035] 在 Y轴移动支架上安装有 X轴移动电机 21和两根导杆， 两根导杆分别设置在 X轴 移动电机 21的两侧， 在两根导杆上设置有打印头 13， 在打印头的上端设置有进 料端， 该进料端用于接收丝状的成型材料， 在打印头 13的下端设置有出料口， 该出料口用于在成型座 12上挤出成型材料。 X轴移动电机 21通过皮带与打印头 13 连接， 当 X轴移动电机 21转动吋， 将通过皮带带动打印头 13沿着导杆滑动， 即打 印头 13在 X轴移动电机 21的驱动下在 X轴方向上移动。
[0036] 在打印头 13上安装有耗材供给驱动电机、 驱动轮和从动轮， 驱动轮与耗材供给 驱动电机连接， 驱动轮和从动轮设置在丝状的成型材料 15的两侧， 驱动轮和从 动轮与成型材料 15呈紧密接触。 当耗材供给驱动电机转动吋， 将带到驱动轮逆 吋针转动， 并且通过驱动轮的转动带动成型材料 15往出料端移动。 在驱动轮和 出料端之间设置有加热腔， 由于所述成型材料包括金属材料和粘结剂， 加热腔 将从进料端进入的成型材料 15加热熔融后， 使得粘结剂呈熔融状态且混合着金 属材料， 再从出料端喷出并放置在成型座上。 优选地， 上述的 X轴移动电机 21、 Υ轴移动电机 22、 Ζ轴移动电机 23和耗材供给电机均为步进电机。
[0037] 参照图 2， 金属三维打印机 1还包括固定在箱体内的清洁装置 14， 清洁装置 14呈 刮板状设置， 且清洁装置 14沿竖直方向布置， 清洁装置 14的上端部和打印头 13 设置在同一水平面上， 为了不影响正常打印， 清洁装置 4不能设置在成型座 12的 上方区域， 否则会干扰打印头 13的行走， 故将清洁装置 4设置在位于成型座 12的 外周的位置上。
[0038] 金属三维打印机的打印方法第一实施例：
[0039] 首先打印头 13在成型座 12上挤出一层成型材料， 随后成型座 12往下移动预设距 离， 然后打印头 13移动至清洁装置 14处， 并与清洁装置 14邻接， 随后打印头 13 移动并与清洁装置分离， 继而继续执行下一层的成像。 通过打印头 13移动与清 洁装置 14发生相对移动并实现熔融成型材料的擦拭。
[0040] 金属三维打印机第二实施例：
[0041] 基于金属三维打印机第一实施例的原理， 清洁装置还可以呈水平方向布置， 同 吋还可以对清洁装置的材质进行优良选取， 具体地， 清洁装置可由耐高温的硅 胶材料或耐高温的海绵材料制作而成。 [0042] 金属三维打印机第三实施例：
[0043] 基于金属三维打印机第一实施例的原理， 本实施例可以将清洁装置进行主动清 洁， 具体地， 在箱体内设置水平移动电机、 导杆和皮带， 通过水平移动电机的 旋转驱动、 皮带传动和导杆引导的作用下， 使得清洁装置能够沿 X方向移动或 Y 方向移动， 而清洁装置的初始位置设置在成型座的外周的位置上。
[0044] 上述实施例中的 X轴移动电机、 Y轴移动电机件、 Z轴移动电机和水平移动电机 构成了本发明的移动电机组件。 同吋提高打印品质， 可将打印头、 成型座、 移 动电机组件、 丝料供给电机和清洁装置均设置在密闭的箱体内， 继而减少在加 热过程中的热量损失。
[0045] 金属三维打印机的打印方法第二实施例：
[0046] 基于金属三维打印机的第三实施例的原理， 打印方法包括， 首先打印头在成型 座上挤出第一层的成型材料， 随后成型座往下移动预设距离， 然后清洁装置移 动至打印头处并与打印头邻接， 随后清洁装置与打印头分离， 通过清洁装置移 动与打印头发生相对移动并实现熔融成型材料的擦拭， 由于成型座往下移动预 设距离， 故打印头和未完成的模型之间存在一定间隙， 故本实施例采用水平延 伸布置的清洁装置较优。
[0047] 由上可见， 采用打印头挤出成像的原理， 成型材料包括金属材料和粘结剂， 利 用 FDM的成型方式进行三维打印， 其成型效率高成本低， 而熔融状态的具有金 属材料的成型材料， 由于其金属材料的原因， 而且从打印头喷出后， 由于外界 环境温度较低， 溶丝遇冷受到内应力的作用变形回缩， 打印头的喷口处溶丝容 易附着在喷口周围， 还会存在余料从喷嘴位置流出情况， 利用清洁装置， 在完 成一层打印后对打印头进行清洁， 具体方式可以采用打印头主动移动清洁， 或 采用清洁装置主动移动清洁， 使清洁装置擦拭或者清洁多余的熔融成型材料， 再进行下一层打印， 继而提高成像品质。
[0048] 三维成型丝料的制造方法实施例和三维成型丝料实施例：
[0049] 上述实施例中的成型材料通过丝状拉伸制作便可形成本实施例中的三维成型丝 料， 以下实施例具体讲述本案三维成型丝料是如何制作而成和成分配比。
[0050] 本发明提供的三维成型丝料包括有金属材料、 粘结剂、 分散剂、 柔韧性增强剂 以及稳定剂， 其中， 金属材料占三维成型丝料的总重量的百分比是 80%至 93%; 粘结剂占三维成型丝料的总重量百分比是 1%至 10%; 分散剂占三维成型丝料的 总重量百分比是 0.1%至 5%; 柔韧性增强剂占三维成型丝料的总重量百分比是 0.1 <¾至5<¾; 稳定剂占三维成型丝料的总重量百分比是 0.1%至 1%。
[0051] 优选地， 金属材料为 Fe/Ni金属材料 （铁镍合金） 、 Wc/Co/Cu金属材料 （碳化 钨 /钴 /铜合金） 、 YBa 2Cu 30 7金属材料 （钇钡铜氧化物） 、 SiC金属材料 （碳化 硅） 、 Si 3N 4金属材料 （氮化硅） 、 Si/Al金属材料 （硅铝合金） 、 Al 20 3/Tic金 属材料 （氧化铝 /碳化钛复合材料） 、 铁金属材料、 钴金属材料、 钼金属材料、 铬金属材料、 铌金属材料、 镍金属材料、 锰金属材料、 钨金属材料、 铜金属材 料、 铝金属材料。
[0052] 优选地， 粘结剂为石蜡基粘结剂、 蜂蜡、 硬脂酸、 巴西棕榈蜡、 乙烯丙烯酸乙 酯、 苯乙烯丙烯腈 （SAN) 树脂、 丙烯腈-苯乙烯-丁二烯共聚物 （ABS) 树脂、 聚对苯二甲酸丁二醇酯 （PBT) 、 聚乙二醇二丙烯酸酯、 二丙二醇甲谜醋酸酯、 2-吡咯烷酮、 聚对苯二甲酸丁二醇酯、 乙基纤维素、 醋酸纤维、 羟丙基纤维素、 低氮硝化纤维素、 乙烯-丁烯纤维素、 聚乙烯缩丁醛、 聚对苯二甲酸乙二醇酯、 聚苯乙烯、 尼龙。
[0053] 优选地， 分散剂为以下物质中的至少一种： 聚酰胺 （PA) 、 聚甲醛 （POM)
、 聚丙烯 （PP) 、 聚乙烯 （PE) 、 乙烯-醋酸乙烯共聚物 （EVA) 、 聚丙烯酸酯 (PEA) 。 稳定剂为氧化锌类热稳定剂。
[0054] 优选地， 柔韧性增强剂为邻苯二甲酸二辛脂和邻苯二甲酸二丁脂的混合物， 邻 苯二甲酸二辛脂和邻苯二甲酸二丁脂的重量百分比为 0.1 : 1至 10: 1。
[0055] 优选地， 金属材料占据的重量百分比是 85%至 90%; 粘结剂占据的重量百分比 是 4%至 9%; 分散剂占据的重量百分比是 0.5%至 3%; 柔韧性增强剂占据的重量 百分比是 0.5%至 3%; 稳定剂占据的重量百分比是 0.5%至 0.8%。
[0056] 第一实施例：
[0057] 本实施例的三维成型丝料的制造方法包括下面的步骤。
[0058] 如图 3所示， 首先， 执行准备步骤 Sl， 取得 80份铁镍合金 （Fe/Ni) 金属材料、 10份石蜡基粘结剂、 0.5份聚酰胺分散剂、 0.5份柔韧性增强剂和 0.5份氧化锌热稳 定剂。 其中， 柔韧性增强剂为邻苯二甲酸二辛脂和邻苯二甲酸二丁脂的混合物 ， 且邻苯二甲酸二辛脂和邻苯二甲酸二丁脂的重量百分比为 1 : 1。
[0059] 然后， 执行挤出步骤 S2， 把上述金属材料、 粘结剂、 分散剂、 柔韧性增强剂 和稳定剂通过螺杆挤出机， 并且经过成型挤出机头在 100°C至 250°C下挤出得到挤 出材料。 如图 4所示， 各组份原料经加料口 30加入到螺杆挤出机 31内， 螺杆 32持 续搅动各组份原料以达到混合均匀的目的， 然后经过成型挤出机头 33挤出得到 挤出材料 34。
[0060] 接着， 执行拉丝步骤 S3， 挤出材料利用拉丝机拉丝得到丝状材料。 如图 5所 示， 是丝状材料 35可以是直线形式， 并且在外力作用发生弯曲变形， 同吋， 在 弯曲变形后这种丝状材料 35不会发生断裂。 在优选的实施方式中， 在拉丝步骤 后还包括冷却步骤， 在冷却步骤中把丝状材料冷却至室温。 拉丝后的丝状材料 的直径为 1.75毫米 ±0.05毫米。
[0061] 最后， 执行卷丝步骤 S4， 由于这种丝状材料 35可以弯曲变形， 因此可以把丝状 材料 35卷曲在丝料盘上。
[0062] 本实施例的三维打印机包括打印平台、 打印头和三维成型丝料， 打印头可相对 于打印平台在三维方向上移动， 三维成型丝料缠绕在 FDM三维打印机的丝料盘 上。 本实施例的三维打印机的具体结构特征和工作原理请参见背景技术部分。 本实施例的三维打印机的成型方法包括初步成型步骤和烧结步骤， 三维成型丝 料采用本实施例的三维成型丝料。
[0063] 在初步成型步骤中， 打印头把三维成型丝料熔融后逐层成型在打印平台上形成 初步固化物体， 且三维成型丝料在打印头内的熔融温度为 180。C至 350。C。
[0064] 在烧结步骤中， 把上述得到的初步固化物体放置在真空环境下、 1200°C高温环 境下烧结固化， 最终完成三维物体的成型， 成型后的物体的密度值为 7.70。 烧结 步骤的具体工艺可参见现有的金属粉末烧结工艺的过程。
[0065] 第二实施例：
[0066] 本实施例的三维成型丝料的制造方法包括下面的步骤。
[0067] 首先， 执行准备步骤： 取得 85份铁镍合金 （Fe/Ni) 金属材料、 10份蜂蜡粘结 齐 ij、 0.3份聚甲醛分散剂、 0.7份柔韧性增强剂和 0.2份氧化锌热稳定剂。 其中， 柔 韧性增强剂为邻苯二甲酸二辛脂和邻苯二甲酸二丁脂的混合物， 且邻苯二甲酸 二辛脂和邻苯二甲酸二丁脂的重量百分比为 0.3: 1。
[0068] 然后， 执行挤出步骤， 把上述金属材料、 粘结剂、 分散剂、 柔韧性增强剂和 稳定剂通过螺杆挤出机， 并且经过成型挤出机头在 160°C至 190°C下挤出得到挤出 材料。
[0069] 接着， 执行拉丝步骤， 挤出材料利用拉丝机拉丝得到丝状材料， 在优选的实 施方式中。 在拉丝步骤后还包括冷却步骤， 在冷却步骤中把丝状材料冷却至室 温。
[0070] 最后， 执行卷丝步骤， 把丝状材料卷曲在丝料盘上。
[0071] 本实施例的三维打印机包括打印平台、 打印头和三维成型丝料， 打印头可相对 于打印平台在三维方向上移动， 三维成型丝料缠绕在 FDM三维打印机的丝料盘 上。 本实施例的三维打印机的具体结构特征和工作原理请参见背景技术部分。 本实施例的三维打印机的成型方法包括初步成型步骤和烧结步骤， 三维成型丝 料采用本实施例的三维成型丝料。
[0072] 在初步成型步骤中， 打印头把三维成型丝料熔融后逐层成型在打印平台上形成 初步固化物体， 且三维成型丝料在打印头内的熔融温度为 200。C至 300。C。
[0073] 在烧结步骤中， 把上述得到的初步固化物体放置在真空环境下、 1200°C高温环 境下烧结固化， 最终完成三维物体的成型， 成型后的物体的密度值为 7.74。 烧结 步骤的具体工艺可参见现有的金属粉末烧结工艺的过程。
[0074] 第三实施例：
[0075] 在执行准备步骤中， 取得 90份铁镍合金 （Fe/Ni) 金属粉末材料、 10份蜂蜡粘 结剂、 0.4份聚甲醛分散剂、 0.6份柔韧性增强剂和 0.3份氧化锌热稳定剂。 其中， 柔韧性增强剂为邻苯二甲酸二辛脂和邻苯二甲酸二丁脂的混合物， 且邻苯二甲 酸二辛脂和邻苯二甲酸二丁脂的重量百分比为 0.5: 1。 成型后的物体的密度值为
7.82。
[0076] 其它步骤与上述第二实施例相同， 不再赘述。
[0077] 第四实施例：
[0078] 在执行准备步骤中， 取得 80份铁镍合金 （Fe/Ni) 金属粉末材料、 10份乙烯丙 烯酸乙酯粘结剂、 0.3份聚丙烯分散剂、 0.7份柔韧性增强剂和 0.2份氧化锌热稳定 齐 1J。 其中， 柔韧性增强剂为邻苯二甲酸二辛脂和邻苯二甲酸二丁脂的混合物， 且邻苯二甲酸二辛脂和邻苯二甲酸二丁脂的重量百分比为 0.3: 1。 成型后的物体 的密度值为 7.75。
[0079] 第五实施例：
[0080] 在执行准备步骤中： 取得 85份铁镍合金 （Fe/Ni) 金属材料、 10份硬脂酸粘结 齐 ij、 0.3份聚甲醛分散剂、 0.7份柔韧性增强剂和 0.4份氧化锌热稳定剂。 其中， 柔 韧性增强剂为邻苯二甲酸二辛脂和邻苯二甲酸二丁脂的混合物， 且邻苯二甲酸 二辛脂和邻苯二甲酸二丁脂的重量百分比为 0.8: 1。 成型后的物体的密度值为 7. 74。
[0081] 第六实施例：
[0082] 在执行准备步骤中： 取得 85份铁镍合金 （Fe/Ni) 金属材料、 10份硬脂酸粘结 齐 ij、 0.3份聚乙烯分散剂、 0.7份柔韧性增强剂和 0.5份氧化锌热稳定剂。 其中， 柔 韧性增强剂为邻苯二甲酸二辛脂和邻苯二甲酸二丁脂的混合物， 且邻苯二甲酸 二辛脂和邻苯二甲酸二丁脂的重量百分比为 1.2: 1。 成型后的物体的密度值为 7. 80。
[0083] 三维成型丝料的第七实施例至第九实施例的部分参数数据如图 6所示。
[0084] 第七实施例至第九实施例的未述及的其它步骤和参数与第一实施例相同， 不再 赘述。
[0085] 第十实施例：
[0086] 在执行准备步骤中： 取得 93份铁镍合金 （Fe/Ni) 金属材料、 6份硬脂酸粘结剂 、 0.5份硅酮粉润滑剂、 0.5份柔韧性增强剂和 0.5份氧化锌热稳定剂。 其中， 柔韧 性增强剂为 3。的 TPE (Thermoplastic Elastomer) 材料， 例如， 3。的苯乙烯类弹性 体。 由于 TPE材料是一种热塑性弹性体材料， 使用 TPE材料作为柔韧性增加剂， 可以提高三维成型丝料的柔韧性。 本实施例成型后的物体的密度值为 7.70。
[0087] 第十一实施例：
[0088] 在执行准备步骤中： 取得 93份铁镍合金 （Fe/Ni) 金属材料、 6份硬脂酸粘结剂 、 0.5份硅酮粉润滑剂、 0.5份柔韧性增强剂和 0.5份氧化锌热稳定剂。 其中， 柔韧 性增强剂为 45°的 TPE材料， 例如， 45°的苯乙烯类弹性体。 本实施例成型后的物 体的密度值为 7.78。
[0089] 第十实施例与第十一实施例中， 采用不同度数的 TPE材料， 其中， 3°的 TPE材 料较为柔软， 45°的 TPE材料比 3°的 TPE材料硬度大。 图 6示出了第十实施例与第 十一实施例的部分参数。
[0090] 对上述第一实施例至第六实施例得到的三维成型丝料进行样本采样， 对这些样 本按照标准 GB/T9341-2008进行测试。 样本的形状为： 长 80.00毫米 （mm)， 宽 10 .00毫米 （mm),厚 4.11毫米 （mm)。 样本测试的速度采用线速度： 10.0毫米 /分钟 (mm/min)。 样本测试的跨度为 66毫米 （mm) 。 样本的测试结果如图 7所示。
[0091] 从图 7可见， 在上述实验条件下， 三维成型丝料的弯曲强度大于 6.9MPa， 从而 实现了金属基三维成型丝料的弯曲变形且不会折断。
[0092] 另外， 对第十一实施例等到的三维成型丝料进行样本采样， 对这些样本按照标 准 ASTM D790-07进行测试。 样本的形状为： 长 127.00毫米 （mm)， 宽 12.70毫米 (mm),厚 3.20毫米 （mm)。 样本测试的速度采用线速度： 10.0毫米 /分钟 （mm/mi n)。 样本的测试结果如图 8所示。
[0093] 从图 8可见， 在上述实验条件下， 三维成型丝料的弯曲强度大于 36MPa， 从而 实现了金属基三维成型丝料的弯曲变形且不会折断。
[0094] 在其它的实施方式中， 本发明的三维成型丝料不包含热稳定剂， 并且依然能够 完成本发明的发明目的， 也就是在不包含热稳定剂的情况下， 三维成型丝料的 弯曲强度能够达到要求， 盘绕在丝料盘上。
[0095] 在其它的实施方式中， 三维成型丝料的组份还包括磁性材料如四氧化三铁， 在 上述三维成型丝料的制造方法中， 在准备步骤和挤出步骤中， 磁性材料粉末与 其它原料如粘结剂等一起加入混合。 三维成型丝料的组份还可以包括着色剂或 者染料， 以使得丝料具有不同的颜色。 柔韧性增强剂例如是增塑剂， 增塑剂例 如为邻苯二甲酸酯类 （或邻苯二甲酸盐类亦称酞酸酯） 的化合物， 邻苯二甲酸 酯类塑化剂包括： 邻苯二甲酸二 （2-乙基己） 酯 （DEHP) 、 邻苯二甲酸二正辛 酯 （DNOP或 DnOP) 、 邻苯二甲酸丁苄酯 （BBP) 、 邻苯二甲酸二仲辛酯 （DC P) 、 邻苯二甲酸二环己酯 （DCHP) 等。 本发明进一步对三维成型丝料的组份 中的物料所起的作用或机理进行了阐述， 但是这种作用机理不对本发明的保护 范围起到限制作用。 由于金属材料与粘结剂之间的密度相差较远， 因此很难形 成均匀的混合效果， 而在组份中增加分散剂之后就可以对原料的均匀混合起到 很好的作用。 本发明的金属材料粉末和粘结剂形成丝料后， 由于这种丝料的脆 性较大， 在弯曲的吋候容易发生折断， 而在组份中增加了柔韧性增强剂如增塑 剂之后， 其柔韧性或者弯曲强度得到了提升， 上述表征结果可以说明。 对于本 发明的三维成型丝料， 当其粘结剂、 增塑剂、 分散剂采用聚合物材料吋， 由于 聚合物分子的分子量是一个较宽的范围， 这就会造成三维成型丝料的熔融温度 出现较大范围的波动， 例如熔融温度范围在 200°C至 230°C内， 而增加了热稳定剂 后， 可以使得三维成型丝料的熔融温度限定在一个较小的范围内， 例如 200°C至 2 05°C之间。
[0096] 最后需要说明的是， 本发明不限于上述的实施方式， 诸如弯曲强度大于 6.9MPa
，弯曲强度大于 6.5MPa的设计等也在本发明的权利要求保护范围之内。
[0097] 工业应用性
[0098] 由于本发明提供的三维成型丝料中含有较多的金属、 玻璃等基材， 以金属作为 基材为例， 本发明的三维成型丝料可以用于金属的三维打印工艺。 并且， 由于 在丝料中添加了柔韧性增强剂， 使得丝料具有良好的弯曲强度， 能够实现丝料 的弯曲并且可以将丝料弯曲成盘状， 有利于丝料的程序。
[0099] 本发明把金属材料制作为可弯曲的金属丝状材料， 同吋能够在 FDM三维打印机 通常设定的温度下形成三维物体， 极大地提升金属三维物体的成型效率。 这种 丝状材料实现了金属丝状材料的弯曲， 弯曲的吋候不会折断， 其在 FDM三维打 印机上的应用实现了突破。
[0100] 采用本发明的丝料进行三维物体的打印， 可以制造金属材质的物体， 与传统工 艺的金属三维物体的成型过程相比， 应用本发明提供的丝状材料后， 采用 FDM 三维打印机进行成型， 成型效率得到显著提升。
[0101] 利用本发明的金属三维打印机， 利用上述配比的成型材料和清洁装置， 在完成 一层打印后对打印头进行清洁， 具体方式可以采用打印头主动移动清洁， 或采 用清洁装置主动移动清洁， 使清洁装置擦拭或者清洁多余的熔融成型材料， 再 进行下一层打印， 继而提高成像品质。

Claims

权利要求书
[权利要求 1] 一种熔融沉积成型的金属三维打印机， 包括
打印头， 所述打印头用于挤出成型材料；
成型座， 所述成型座用于承载所述成型材料；
移动电机组件， 所述移动电机组件包括 X轴移动电机、 Y轴移动电机 件和 Z轴移动电机， 所述 X轴移动电机用于驱动所述打印头在 X轴方向 上的移动；所述 Y轴移动电机用于驱动所述打印头在 Y轴方向上的移动 ， 所述 z轴移动电机用于驱动所述成型座在 Z轴方向上的移动， 丝料供给电机， 所述丝料供给电机用于输送丝状的所述成型材料至所 述打印头中；
其特征在于：
所述成型材料包括金属材料和粘结剂；
所述金属三维打印机还包括清洁装置， 所述清洁装置和所述打印头设 置在同一水平面上， 所述清洁装置位于所述成型座的外周的位置上， 所述打印头可与所述清洁装置邻接。
[权利要求 2] 根据权利要求 1所述的金属三维打印机， 其特征在于：
所述清洁装置呈刮板状设置。
[权利要求 3] 根据权利要求 2所述的金属三维打印机， 其特征在于：
所述清洁装置沿竖直方向布置。
[权利要求 4] 根据权利要求 2所述的金属三维打印机， 其特征在于：
所述清洁装置沿水平方向布置。
[权利要求 5] 根据权利要求 1所述的金属三维打印机， 其特征在于：
所述移动电机组件还包括水平移动电机， 所述水平移动电机用于驱动 所述清洁装置在水平面上移动。
[权利要求 6] 根据权利要求 1所述的金属三维打印机， 其特征在于：
所述金属三维打印机还包括箱体， 所述箱体围成密闭的腔体， 所述箱 体用于装载所述打印头、 所述成型座、 所述移动电机组件、 所述丝料 供给电机和所述清洁装置。
[权利要求 7] 根据权利要求 1至 6任一项所述的金属三维打印机， 其特征在于： 所述清洁装置由硅胶材料制作而成。
[权利要求 8] 根据权利要求 1至 6任一项所述的金属三维打印机， 其特征在于： 所述清洁装置由海绵材料制作而成。
[权利要求 9] 一种熔融沉积成型的金属三维打印机的打印方法， 其特征在于， 所述 金属三维打印机包括：
打印头， 所述打印头用于挤出成型材料， 所述成型材料包括金属材料 和粘结剂；
成型座， 所述成型座用于承载所述成型材料；
移动电机组件， 所述移动电机组件包括 X轴移动电机、 Y轴移动电机 件和 Z轴移动电机， 所述 X轴移动电机用于驱动所述打印头在 X轴方向 上的移动；所述 Y轴移动电机用于驱动所述打印头在 Y轴方向上的移动 ， 所述 Z轴移动电机用于驱动所述成型座在 Z轴方向上的移动， 丝料供给电机， 所述丝料供给电机用于输送丝状的所述成型材料至所 述打印头中；
清洁装置， 所述清洁装置和所述打印头设置在同一水平面上， 所述清 洁装置位于所述成型座的外周的位置上，
所述打印方法包括：
所述打印头在所述成型座上挤出所述成型材料； 所述打印头移动至所述清洁装置并与所述清洁装置邻接；
所述打印头与所述清洁装置分离。
[权利要求 10] —种熔融沉积成型的金属三维打印机的打印方法， 其特征在于， 所述 金属三维打印机包括：
打印头， 所述打印头用于挤出成型材料， 所述成型材料包括金属材料 和粘结剂；
成型座， 所述成型座用于承载所述成型材料；
移动电机组件， 所述移动电机组件包括 X轴移动电机、 Y轴移动电机 件、 Z轴移动电机和水平移动电机， 所述 X轴移动电机用于驱动所述 打印头在 X轴方向上的移动；
所述 Y轴移动电机用于驱动所述打印头在 Y轴方向上的移动， 所述 z轴 移动电机用于驱动所述成型座在 z轴方向上的移动，
丝料供给电机， 所述丝料供给电机用于输送丝状的所述成型材料至所 述打印头中；
清洁装置， 所述清洁装置和所述打印头设置在同一水平面上， 所述清 洁装置位于所述成型座的外周的位置上， 所述水平移动电机用于驱动 所述清洁装置在水平面上移动，
所述打印方法包括：
所述打印头在所述成型座上挤出所述成型材料；
所述成型座往下移动预设距离；
所述清洁装置移动至打印头处并与所述打印头邻接；
所述清洁装置与所述打印头分离。
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