JP2021527578A - Addition-manufactured structures and methods for forming the same structures - Google Patents

Abstract

Addition-manufactured structures and methods of forming and using structures. The object (200) can be printed at least partially on the attachment portion (240). The attachment portion can be attached to the object at the time of printing. The object does not need to be removed from the attachment part. The need to provide a printed surface (110) to allow easy removal of the object is eliminated. The object may be a flat panel, eliminating the need to print large flat layers using additive manufacturing. The attachment portion can be cut before printing, which eliminates the need for trimming to be performed after printing. The attachment portion can be formed from a material having one or more selected properties to extend the functionality of the object. Secondary work for attaching the attachment portion to the object after printing can be eliminated.

Description

Related application

The present application claims priority to US Provisional Patent Application No. 62/683527 filed June 11, 2018. Priority to the provisional patent application is expressly asserted, whereby the entire disclosure of the provisional patent application is incorporated herein by reference in its entirety for all purposes.

The disclosed embodiments generally relate to addition manufacturing, and more specifically to, but not to exclude others, addition-manufactured structures and methods for forming the structures.

Three-dimensional (3D) printing, also known as additive manufacturing, is a technique that deposits material only where it is needed, and is therefore a conventional manufacturing that generally forms parts by reducing or removing material from bulk material. It produces significantly less material waste than technology. The first articles printed in three dimensions (3D) were generally models, but by creating functional components in more complex systems, such as hinges, tools, and structural elements. The industry is progressing rapidly.

In a typical addition manufacturing method, a 3D object is created by forming a layer of material under computer control. A challenge that arises for more advanced 3D printed articles is to provide a printed surface for printing. For example, in a 3D printing process based on the extrusion deposition method, the printed surface may adhere sufficiently strongly to the printed 3D object to prevent the 3D object from moving throughout the printing period. It is necessary to provide appropriate adhesion. In addition, the printed surface should generally allow separation from the 3D object without damaging or contaminating the 3D object. Existing printed surfaces are often difficult and time consuming to remove from 3D objects. The texture that remains on the 3D object at the time of removal is always undesirable. Additionally, if different materials need to be incorporated into the 3D object, secondary work (eg, bonding or fixing the second material to the 3D object) is required. Secondary operations often require additional pretreatment (eg, cleaning, polishing and / or undercoating) before the adhesive or fixture can be provided, and this additional pretreatment Is time consuming and can cause additional mistakes due to manual processes, making it difficult to access 3D objects during manufacturing.

Additions for forming 3D articles on a large scale (ie, generally having at least one dimension larger than 5 feet (1.524 m)) can be referred to as large additions. A system (or technology) for large-scale addition manufacturing can be referred to as a large-scale addition manufacturing system (or technology). Typical large scale additive manufacturing systems are, for example, Big Area Additive Manufacturing (BAAM) 100 ALPHA available from Cincinnati Incorporated in Harrison, Ohio or Large Scale Additive Manufacturing available from Thermwood Corporation in Dale, Indiana. Includes (LSAM) machine. Typical systems that utilize extrusion deposition for large scale addition manufacturing include BAAM 100 ALPHA and LSAM machines.

In recent years, large-scale additive manufacturing has become a field of greater research, utilization and technological advancement due to improved material properties and increasing demand for customized large structures. For example, Local Motors in Phoenix, Arizona first used large-scale additive manufacturing or large-scale extrusion deposition to print vehicles. However, large-scale additive manufacturing also faces unique challenges.

Methods for forming structures in smaller scale additions may not necessarily apply to large scale additions. In smaller add-on manufacturing, it can be difficult to set up a suitable printed surface, but this difficulty can be particularly serious in large-scale add-on manufacturing and present unique challenges. For example, in small-scale additive manufacturing, the printed surface can be coated with glue stick or painter's tape, but this coating is time consuming and can be impractical on a large scale. In addition, large-scale extrusion deposition methods can take a long time to solidify the beads. Therefore, each printed layer may have its own solidification progression. In addition, the printed layers are large and therefore the relative magnitude of deformation between adjacent layers is large. The stress generated between adjacent layers can be significant.

In some conventional large-scale systems, an acrylonitrile butadiene styrene (ABS) sheet is used to coat the printing bed and can be attracted by the vacuum applied through the printing bed to provide high adhesion. .. However, the printing bed can become hot when heated, making it difficult to install ABS sheets or walk on the printing bed during large-scale addition manufacturing. ABS sheets can leave non-uniform gaps in large prints. This is because a plurality of ABS sheets must be lined up and taped to cover a large size printing bed. In addition, ABS sheets can deform under high stress during printing. Another issue is that there may be gaps between the plurality of ABS sheets, which can affect print quality. Therefore, the non-uniformity of the gaps and the presence of gaps between the sheets can significantly affect the print quality.

When deformed, the ABS sheet is no longer held by vacuum and may lift out of the printing bed. For example, in a large extrusion deposition process, bead solidification can take a long time. Therefore, each printed layer has its own solidification process. In addition, due to the large size of the printed layers, the relative magnitude of deformation between adjacent layers is large. The stress generated between adjacent layers can be significant. Lifting of the ABS sheet can cause abrupt stress relaxation. Objects with such deformations may appear to be poorly shaped. Deformation of the object may reduce the distance between the object and the print head during printing and may increase the width of the beads that are subsequently deposited on the object, leading to printing defects.

In some conventional large-scale systems, boards, such as wood particle board, can be coated with glue, such as woodworking bonds, and used. Plastic pellets can be sprayed over the woodworking bond. The roughness provided by the pellets can help keep the object in place during printing. However, in large-scale addition production, spraying pellets on a board takes time, and it becomes difficult to uniformly disperse glue and pellets during production. Any non-uniform dispersion can result in non-uniform adhesion of the object, which can result in deformation of the object. When an object is removed from the board, a large amount of slippery pellets can fall to the ground, causing great clutter. Moreover, the board cannot be easily reused due to the loss of pellets. Finally, this method causes pellet adhesion to the bottom layer of the print, reducing the quality and flatness of this layer. In general, this bottom layer must be removed by a secondary operation.

Another challenge is printing large flat surfaces. For example, in a large extrusion deposition process, the time between printing two adjacent layers can be long. Of the two adjacent layers, the first layer may be sufficiently solidified before the second layer is printed. This can result in inadequate adhesion between the two layers. Additionally, when printing large flat surfaces, it can be difficult to achieve good overlap in the y direction. Overfilling after only a few adjacent layers can lead to compounding errors that can destroy the printhead. Overfilling can clog the tamper (BAAM) or roller (LSAM) and stop work. On the other hand, underfilling can result in inadequate mechanics.

Another challenge that arises for more advanced 3D printed articles is to print overhang structures. For example, many structural materials have a poor ability to bridge gaps under gravity without deformation (eg slack) or fracture. The overhang structure can include a portion of the printed structure that extends into space at least in a direction that is at least partially orthogonal to gravity from the main part of the printed structure. The bridge structure can include a typical overhang structure with two opposite end regions, each connected to a printed structure.

Smaller add-on manufacturing can be difficult to form overhang structures, but this difficulty is particularly serious in large-scale add-on manufacturing and presents specific challenges. In large-scale extrusion deposition processes, the overhang structure is usually large. The magnitude of deformation of the overhang structure can be significant. For example, in a large extrusion deposition process, a large extruded bead retains heat significantly longer and remains in a rubber or molten state for a long time after the nozzle attempts to deposit the bead in the desired position. Stay. While the bead solidifies, the bead may not be able to maintain its dimensions due to the weight of the bead itself and the weight of the material printed on the bead. A rapid solidification process, such as spraying liquid nitrogen onto the beads, may be utilized to accelerate the solidification, but the rapid solidification process significantly reduced the adhesion between the printed layers and was printed. May weaken the strength of large structures. In contrast, in a small extrusion deposition process, a fan can be used to rapidly solidify the material as it exits the nozzle, making it easier to print overhangs.

To assist in printing the overhang structure, the support structure can be printed at the same time as the object, and then the overhang structure can continue to be printed on the support structure. However, in large-scale additive manufacturing, such support structures are costly in many resources, such as materials, printing time and energy consumption. Furthermore, the characteristics of the support structure cannot be flexibly selected, which may make it difficult to remove the support structure. Even if a sparse infill pattern is used to print the support structure, it can still be difficult to remove, and the problems mentioned above for printing across gaps in the sparse infill support structure still exist.

With the above in mind, improvements and / or alternatives to improve the additive manufacturing process to produce printed surfaces that overcome the shortcomings of existing solutions and minimize the number of secondary operations. Target or additional solutions are needed.

The present disclosure relates to additionally manufactured structures and methods for forming and using the structures.

According to the first aspect disclosed herein, it is a method for addition production.
Steps to place the attachment part on the printer,
A step of printing an object, at least in part, onto an attachment portion, such that the attachment portion binds to the object by absorbing heat during the printing step, by locking to the object, or by a combination thereof. Consists of the steps to print and
The method including is shown.

In some embodiments of the disclosed method, the printer is part of a large-scale additive manufacturing system.

In some embodiments of the disclosed method, the attachment portion is made of a first material and the object is made of a second material that is different from the first material.

In some embodiments of the disclosed method, the placement step comprises placing an attachment portion formed from a thermoplastic material, a thermosetting material or a combination thereof, at least in part.

In some embodiments of the disclosed method, the placing step comprises placing an attachment portion made of a fiber reinforced thermoplastic material.

In some embodiments of the disclosed method, the attachment portion comprises a perforated panel having one or more openings and placed on the receiving surface, and the printing step is one portion of the object. A step of printing an object onto an attachment portion so as to form one or more caps that flow through the above openings and are widened by contacting the receiving surface and configured to lock on a perforated panel. including.

In some embodiments of the disclosed method, the placing step comprises placing an attachment moiety containing a polyetherimide (PEI) foam, a polyethersulfone (PES) foam or a combination thereof.

In some embodiments of the disclosed method, the placing step is
A step of printing multiple layers that are stacked in the stacking direction and collectively form a closed loop,
A step of filling the space formed by the closed loop with a spray foam configured to expand in the space,
The step of cutting the inflated spray foam so that it is flat with the top layer of the multiple layers,
including.

In some embodiments of the disclosed method, the method further comprises performing a surface treatment on the attachment portion prior to the step of printing.

In some embodiments of the disclosed method, the steps performed include performing plasma treatment on the attachment portion.

In some embodiments of the disclosed method, the steps performed include performing plasma treatment on an attachment portion formed of metal.

In some embodiments of the disclosed method, the attachment portion is configured to bond to the object by absorbing heat from the object, at least in part, during the printing step.

In some embodiments of the disclosed method, the method is
The base part and
With a bonding layer on the base part, which joins the object during the printing step,
Further includes the step of preparing the attachment portion including.

In some embodiments of the disclosed method, the step of preparation comprises placing the bond layer on the base portion, the bond layer absorbing heat from the object at least partially during the printing step. It is configured to connect the base part to the object.

In some embodiments of the disclosed method, the step of preparation comprises placing the bond layer on the base portion, the bond layer being formed from thermoplastic polyurethane at least in part.

In some embodiments of the disclosed method, the step of preparation comprises placing the bond layer on the base portion, and the bond layer comprises a sheet of honeycomb pattern.

In some embodiments of the disclosed method, the step of preparation comprises placing the bond layer on the base portion, where the bond layer is polyethylene terephthalate glycol (PETG), polyethylene terephthalate (PET) or a combination thereof. Includes sheets formed from.

In some embodiments of the disclosed method,
The base portion comprises a perforated panel having one or more openings and arranged on the receiving surface.
The steps to prepare include printing the bond layer onto the base portion.
A portion of the binding layer flows through one or more openings and forms one or more caps that are widened by contact with the receiving surface and are configured to lock onto a perforated panel.

In some embodiments of the disclosed method, the steps to prepare are
A step of printing a base portion containing one or more layers by a printer,
The step of placing the binding layer on the base part,
including.

In some embodiments of the disclosed method, the method is
A step of printing a foundation structure with one or more foundation layers,
Steps to place the secondary bond layer on the foundation structure,
Including
The placement step includes attaching the attachment portion to the foundation structure via a secondary bond layer.

In some embodiments of the disclosed method, the arranging step comprises arranging the attachment portion including the flat panel, and the printing step comprises printing the object entirely on the flat panel.

In some embodiments of the disclosed method, the printing step is
With the step of printing at least one first layer structure,
After the placement step, the first layer structure and the step of printing the second layer structure on the attachment portion, wherein the attachment portion is configured to be coupled to the second layer structure, print. Steps and
including.

In some embodiments of the disclosed method, the method further comprises placing the support structure on the printer, and the step of placing the attachment portion comprises placing the attachment portion on the support structure.

In some embodiments of the disclosed method, the method further comprises removing the support structure from the attachment portion after the step of printing the second layer structure.

In some embodiments of the disclosed method, the method further comprises the step of preparing a support structure, at least partially formed from foam.

In some embodiments of the disclosed method, the method further comprises the step of printing the support structure using a printer.

In some embodiments of the disclosed method, the printing step comprises printing the second layer structure, which is at least partially supported by the attachment portion, during the step of printing the second layer structure. ..

In some embodiments of the disclosed method, the step of printing at least one first layer structure comprises printing two first layer structures and the attachment portion comprises two first layers. Arranged between the structures.

In some embodiments of the disclosed method, the step of printing the second layer structure bridges the two first layer structures and at least partially during the step of printing the second layer structure. It involves printing a second layer structure supported by the attachment portion.

In some embodiments of the disclosed method, the step of printing the two first layer structures is to attach the attachment portion at a high position above the printing substrate of the printer without contacting the printing substrate of the printer. Includes the step of printing two first layer structures, each with a recess for containment.

In some embodiments of the disclosed method, the method further comprises placing a secondary bond layer at the bottom of the recess so that the secondary bond layer attaches the attachment portion to the first layer structure. It is configured in.

In some embodiments of the disclosed method, the second layer structure is at least one fixing member formed in the edge region of the attachment portion and configured to secure the attachment portion so as not to exit the recess. including.

In some embodiments of the disclosed method, the second layer structure does not extend continuously across the attachment portion.

In some embodiments of the disclosed method, there is a gap between the attachment portion and at least one first layer structure.

In some embodiments of the disclosed method,
The step of printing at least one first layer structure comprises printing one or more first layers printed in the printing direction and laminated in the stacking direction.
The step of printing the second layer structure includes printing one or more second layers printed in the printing direction and laminated in the stacking direction.

In some embodiments of the disclosed method, the step of printing at least one first layer structure prints the first layer structure having side walls at a predetermined lateral angle to the printing direction. Including steps, the lateral angle is 35 to 90 degrees.

In some embodiments of the disclosed method, the step of printing at least one first layer structure is the step of printing the first layer structure having side walls with lateral angles that vary along the side walls. include.

In some embodiments of the disclosed method, the step of printing at least one first layer structure is a first layer structure having a curved side wall with a diminishing lateral angle along the stacking direction. Includes steps to print.

In some embodiments of the disclosed method, at least one first layer structure and attachment portion each has a joint side proximal to the second layer structure, and the step of placing the joint side is Includes a step of arranging the attachment portions so that they are coplanar.

According to another aspect disclosed herein, the structure is at least partially formed by addition manufacturing.
An object containing one or more layers stacked in the stacking direction,
Attachments that are laminated with the object in the stacking direction and are attached to the object by locking it to the object or by combining them by absorbing the heat generated during printing of the object.
Structures containing are shown.

In some embodiments of the disclosed structures, the attachment portion comprises a perforated panel with one or more openings, and a portion of the object extends through the one or more openings and is perforated. It forms one or more caps configured to lock onto a panel.

It is a figure which shows an embodiment of the system for addition manufacturing exemplary. FIG. 5 is an exemplary illustration of an alternative embodiment of the system of FIG. 1 in which the system forms a structure that includes an object and an attachment portion. FIG. 2 is a typical cross-sectional view showing an alternative embodiment of the system of FIG. 2A, wherein the attachment portion has one or more openings. FIG. 2 is a typical perspective view showing an alternative embodiment of the system of FIG. 2B, in which the attachment portions have an array of openings. It is a typical top-level flowchart which shows one embodiment of the method for addition manufacturing based on the system of FIG. FIG. 2 is a typical cross-sectional view showing an alternative embodiment of the structure of FIG. 2A, wherein the attachment portion includes a binding layer and a base portion. FIG. 5 is a typical cross-sectional view showing an alternative embodiment of a system for forming the structure of FIG. 4 in which the base portion has one or more openings. FIG. 5 is a typical perspective view showing an alternative embodiment of the structure of FIG. 4B, where the base portion has an array of openings. FIG. 5 is a typical cross-sectional view showing an alternative embodiment of the structure of FIG. 2A in production, wherein the object has a first layer structure. FIG. 5 is a typical cross-sectional view showing an alternative embodiment of the structure of FIG. 5 being manufactured, in which the attachment portion is located in the system. FIG. 6 is a typical cross-sectional view showing an alternative embodiment of the structure of FIG. 6 being manufactured, in which a second layer structure is printed on the attachment portion. It is a typical flowchart showing an alternative embodiment of the method of FIG. 3, wherein the method comprises printing a first layer structure. FIG. 5 is a typical cross-sectional view showing an alternative embodiment of the structure of FIG. 7 in which the attachment portion is attached to the support structure. FIG. 5 is a typical cross-sectional view showing an alternative embodiment of the structure of FIG. 9 with the support structure removed from the attachment portion. The object has first and second layer structures as well as attachment portions, the second layer structure being printed over the attachment portion and the gap separating the first layer structure and the attachment portion. FIG. 6 is a typical cross-sectional view showing another alternative embodiment of the structure of FIG. It is a typical cross-sectional view showing another alternative embodiment of FIG. 7 in which the object has an inclined side wall. The first layer structure is a typical cross-sectional view showing another alternative embodiment of the structure of FIG. 7 having curved side walls. FIG. 5 is a typical cross-sectional view showing another alternative embodiment of the structure of FIG. 7 in which the second layer structure has a tilt angle. FIG. 5 is a typical cross-sectional view showing an alternative embodiment of the structure of FIG. 7, wherein the structure has a third layer structure. It is a typical flowchart showing another alternative embodiment of the method of FIG. 3, wherein the method comprises printing a third layer structure. FIG. 6 is a typical cross-sectional view showing another alternative embodiment of the structure of FIG. 7 in production, wherein the first layer structure has a support member. It is a typical cross-sectional view showing another alternative embodiment of the structure of FIG. 17 in which the second layer structure is printed on the attachment portion. FIG. 5 is a typical cross-sectional view showing another alternative embodiment of the structure of FIG. 18 in which the support member has a non-uniform side wall. It is a typical figure showing another alternative embodiment of the structure of FIG. 17 in which the attachment portion is attached to the secondary bond layer. It is a typical diagram showing another alternative embodiment of the system of FIG. 2A, in which the attachment portion is attached to the foundation structure. It is a typical figure which shows one Embodiment of the control system for controlling the system of FIG.

As a reminder, the drawings are not to scale and elements with similar structures or functions are generally represented by the same reference numerals throughout the drawings for illustrative purposes. Also, as a reminder, the drawings are only intended to facilitate the description of preferred embodiments. The drawings do not show all aspects of the described embodiments and do not limit the scope of the present disclosure.

FIG. 1 shows a typical system 100 for additive manufacturing. The system 100 can include a 3D printer configured to print the object 200 by extrusion deposition (or material extrusion). The printhead 120 is shown to have nozzles configured to deposit one or more polymer layers on the print substrate 140 to form the object 200. The printing substrate 140 is shown in FIG. 1 to provide a printing surface 110 for receiving the initial printing material deposited from the printing head 120.

The printing substrate 140 is shown to include a printing bed 160. The print bed 160 can provide a uniform or flat surface. The printing bed 160 can include a heated and / or unheated table. The printing substrate 140 can include any alternative type of printing bed and any other intermediate structure (not shown) that covers the printing bed at least partially. The stacking direction of the layers is the z direction, and the printing direction is the x direction.

Although FIG. 1 shows the addition manufacturing performed by the system 100 utilizing extrusion deposition, any other system or process for performing the addition manufacturing can be utilized in the present disclosure. Typical processes for addition manufacturing can include binder injection, directional energy deposition, material injection, powder bed melt bonding, sheet lamination, liquid bath photopolymerization, stereolithography or combinations thereof.

As mentioned above, it is generally desirable to remove the object 200 from the printed surface 110. Therefore, the system 100 for addition manufacturing has a printed surface to prevent damage or contamination to the object 200 and / or to provide a temporary bond for subsequent mounting via fixtures and / or pins. It provides a suitable bond between 110 and the initially printed layer.

In addition, currently available methods and systems are unable to provide reliable printed surfaces with adequate adhesion, are unable to produce large flat surfaces with good adhesion, and are sturdy. Since it is not possible to produce large-scale add-manufactured parts with overhang structures, add-on structures and methods for forming the same structures that can overcome the drawbacks shown above are desirable. It can be proven that it can provide a foundation for a wide range of applications, such as additive manufacturing for vehicles and / or building structures.

The structures and methods presented in the present disclosure are applied to solve technical problems in large-scale addition manufacturing, but the structures and methods are not limited to any smaller additions. It can be applied to manufacturing, eg medium scale and / or small scale additive manufacturing. For example, in some embodiments, due to machine size, large-scale addition manufacturing provides easy access to implement the embodiments disclosed herein (eg, parts are larger, while printing). There is more space to work on the machine). However, it will be apparent to those skilled in the art that the embodiments disclosed herein can be applied to smaller additive manufacturing systems.

With reference to FIG. 2A, an alternative embodiment of a typical system 100 is shown. The attachment portion 240 is arranged and shown on the printing substrate 140. Attachment portion 240 may be permeable and / or opaque. The attachment portion 240 is shown in FIG. 2A to have the shape of a flat panel. A typical attachment portion 240 can be formed by stamping, milling, die cutting, forming, casting, laser cutting and / or water jet cutting, additive manufacturing, or a combination thereof to cut the sheet material. can. In one embodiment, the attachment portion 240 can be pre-cut to a selected shape and size prior to being placed in the system 100. Advantageously, the attachment portion 240 can be replaced by a large flat section of the object 200 that may be otherwise printed. In some embodiments, the attachment portion 240 comprises one or more layers 202 of the object 200. Additional and / or alternative, the typical attachment portion 240 can be formed using additional manufacturing.

The object 200 and the attachment portion 240 can be formed from uniform and / or different materials. In one embodiment, the object 200 can be formed from a first material and the attachment portion 240 can be formed from a second material that is different from the first material. For example, as further described below, the object 200 can include a pre-printed carbon fiber-filled ABS printed on an attachment portion 240 that includes a polycarbonate honeycomb sheet and / or an ABS honeycomb sheet. In another example, the object 200 can include a foamed polymer (eg, PES). The foamed polymer (eg, PES) can be attached to the plate or structure as an attachment portion 240, which allows printing on the upper side of the object 200 to secure the polymer to the plate or structure. In yet another example, a closed loop can be printed for multiple layers, followed by a pause to fill the closed loop with two-part spray foam. After a short period of time (eg, 30 seconds), the expanded foam can be cut to flatten with the printed top layer and act as a printed surface. Additional and / or alternative, the object 200 can be formed from polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG) and / or the like.

The attachment portion 240 can be placed on the printing substrate 140 before printing the object 200 (or while printing the object 200). The attachment portion 240 is predetermined to the printed substrate 140 in any suitable form, including, for example, vacuuming, taping, tightening, bolting, and / or applying an adhesive (removable and / or permanent). Can be fixed in position. Additionally and / or alternatively, the attachment portion 240 may selectively or automatically engage and / or disengage the attachment portion 240 and the printing substrate 140 in order to bond or disconnect the attachment portion 240 and the printing substrate 140 from each other. Predetermined for the printed substrate 140 through collaborative irregularities, including any combination of engaging elements such as blocks, tabs, pockets, slots, slopes, locking pins, cantilever members, support pins, etc. Can be fixed in position.

The object 200 is shown to include one or more layers 202 stacked in the z direction. The object 200 can be manufactured by utilizing additional manufacturing. The print head 120 can print the object 200 on the attachment portion 240 at least partially. A typical object 200 can be formed from a thermoplastic material containing ABS, polycarbonate, polyamide, poly (p-phenylene oxide) (PPO), poly (p-phenylene ether) (PPE) or a combination thereof. The object 200 can also be filled with carbon and / or glass when printed on a large scale to limit warpage, promote flow and / or affect mechanics.

In one embodiment, the object 200 can be formed, at least in part, from thermoplastic polyurethane (TPU). A typical TPU can include an ester-based TPU. In a non-limiting example, ester-based TPUs can have a shore hardness of 85A-98A. The TPU can print in 3D with a printing bed 160 kept at room temperature (shown in FIG. 1). Advantageously, the higher operating temperature causes strain on the print bed 160, so keeping the print bed 160 at room temperature can extend the life of the print bed 160 and facilitate the print bed related procedures performed by the operator. can do. Additional and / or alternative, the TPU may be recyclable and can generate less environmental waste.

By contacting the object 200 during printing, the attachment portion 240 can be coupled to the object 200. Optionally, the attachment portion 240 can contact the initially printed layer 202 of the object 200 for a selected amount of time and then bond to the object 200 with optimum strength. In other words, the attachment portion 240 can bond the initially printed layer 202 of the object 200 to the object 200 with optimum strength after it has been cooled or solidified for a selected period of time. In other words, the object 200 can be attached to the attachment portion 240 by contacting the connecting surface 242 of the attachment portion 240. The coupling surface 242 may be the surface of the attachment portion 240 proximal to the object 200. As a result, the structure 300 can be formed. The structure 300 can include an object 200 and an attachment portion 240. In other words, when the printing of the object 200 is completed, the entire structure 300 can be removed from the printing substrate 140 while the attachment portion 240 is attached to the object 200. In one embodiment, the attachment portion 240 can be permanently attached to the object 200.

In one embodiment, the attachment portion 240 can be attached to the object 200 by contacting and / or being heated by the object 200. For example, the attachment portion 240 can absorb heat from the object 200 during printing and / or, for example, if the printing substrate 140 includes a table to be heated, it can absorb heat from the printing substrate 140. Can be done. In some embodiments, the attachment portion 240 can be further anchored to the object 200 using additional fixtures and / or attachments (not shown), for example as a secondary task.

FIG. 2A shows an attachment portion 240 including a base portion 243. The base portion 243 may be a solid portion of the attachment portion 240 and is shown in contact with the object 200. A typical base portion 243 can be formed from any material, including metals, polymers, ceramics, semiconductors or combinations thereof. A typical base portion 243 can be formed from a thermoplastic material and / or a thermosetting material, a typical base portion 243 is a polyetherimide (PEI), a polyethersulfone (PES), PET, PETG. , ABS, Polycarbonate, Polyamide, PPO, PPE, TPU or a combination thereof. When heated, the base portion 243 melts and can bond to the object 200. Optionally, the base portion 243 is a smooth texture, foam texture, closed cell foam texture, open cell foam texture, corrugated texture, randomly roughened texture, patterned texture (eg, dimples, spots, geometry). Etc.) and / or can have a honeycomb texture. For example, base portion 243 can include PEI foam and / or PES foam. In another example, the base portion 243 can include a cardboard and / or a roughened surface for printing.

In one embodiment, the base portion 243 can include a sheet or other form of thermoplastic and / or thermosetting material of any shape. Thermoplastic materials and / or thermosetting materials can be selectively fiber reinforced. For example, the fabric can be dipped and / or dipped in a thermoplastic material to form a fiber reinforced thermoplastic sheet. In another example, the thermoplastic material can be 3D printed and can be formed from, for example, thermoplastic polyurethane (TPU). A cloth can be embedded in the TPU during 3D printing to form a fiber reinforced TPU. The fabric can include any flexible material, including a mesh of natural and / or artificial fibers. Typical fibers can include yarns or threads. The fabric can be formed by any suitable process, including weaving, knitting, crocheting, knotting, felting, matting, shrink weaving and / or pressurization, for example. The fabric can include any organic fabric, semi-synthetic fabric, synthetic fabric, woven fabric, non-woven fabric or a combination thereof. Typical organic fabrics can include cotton, denim, canvas, duck canvas, linen, silk, wool and / or the like. Typical semi-synthetic fabrics can include rayon and / or the like. Typical synthetic fabrics can include polyester, acrylic, polyamide, polymeric microfibers and / or the like. Additionally and / or alternatives, the thermoplastic and / or thermosetting material can be fiber reinforced with any suitable reinforcing fiber, including carbon fiber, glass fiber and / or the like.

In one embodiment, the base portion 243 is formed of a thermoplastic material and / or a thermosetting material, and when the printing substrate 140 is heated, a textured and / or patterned sheet is referred to as the base portion 243. It can be placed between the printing substrate 140 and the printing substrate 140. The texture of the sheet can be imprinted on the base portion 243.

In some embodiments, the object 200 is not removed from the attachment portion 240, and thus advantageously provides a printed surface 110 (shown in FIG. 1) to allow easy removal of the object 200. The problem of doing is eliminated. The attachment portion 240 can include a flat panel, which can advantageously eliminate the need to print a large flat layer using additive manufacturing.

Additionally, if the attachment portion 240 is pre-cut before printing the object 200, it is not necessary to perform post-separation or post-print trimming after printing. Advantageously, the processing of the object 200 can be simplified. The attachment portion 240 can be mechanically formed from a strong material, which provides a strong high-strength layer to the object 200, resulting in a lighter and stronger structure 300. In addition, the attachment portion 240 can function as a shear panel for the printed object 200. For example, the attachment portion 240 includes a three-dimensionally printed vehicle lower chassis closeout panel.

Additional and / or alternative, the attachment portion 240 can be formed from a material having one or more selected properties, which can advantageously extend the functionality of the structure 300. For example, the attachment portion 240 may be adiabatic, semi-conductive and / or conductive. Additional and / or alternative, the attachment portion 240 may be electrically insulating, semi-conductive and / or conductive. For example, the attachment portion 240 formed from PEI foam and / or PES foam may be insulating. Additional and / or alternative, the attachment portion 240 can provide a mechanical improvement to the structure 300 and / or a chemical barrier and / or a moisture barrier.

Since the attachment portion 240 can be coupled at the same time as printing the object 200, secondary work for attaching the attachment portion 240 to the object 200 can be eliminated and / or reduced. Advantageously, time and labor costs can be saved and the manufacturing process can be simplified. Advantageously, the existing removable print surface (as described above) can be provided and the additional problems of utilization / reuse can be avoided.

System 100 is shown to include a selective machine tool 130. The machine tool 130 can remove the selected portion and / or the attachment portion 240 of the object 200 during and / or after printing the object 200. A typical machine tool 130 can include a roll machine, a lathe, any type of cutting machine or a combination thereof. The machine tool 130 can be installed at any suitable position on the system 100. FIG. 2A shows a machine tool 130 directly and / or indirectly connected to the printing bed 160 for illustration purposes only. The printhead 120 and machine tool 130 can be controlled by a uniform and / or different control system 500 (shown in FIG. 22).

FIG. 2A shows the attachment portion 240 as a flat panel 240 perpendicular to the z direction for illustration purposes only, but the attachment portion 240 is arranged in any suitable orientation without limitation. It can have any shape of choice.

With reference to FIG. 2B, the attachment portion 240 is shown to have a flat shape and to have a plurality of openings 245 (indicated by dashed lines) penetrating the attachment portion 240 in the z direction. In other words, the attachment portion 240 can include a perforated panel. The object 200 is shown to be formed by printing a bead on the attachment portion 240. In the molten state, the bead material is pushed into the opening 245 in direction A until it contacts the receiving surface 180. A typical receiving surface 180 was placed under the printed substrate 140 (shown in FIG. 2A), the previously printed layer 202 (shown in FIG. 2A) and / or the attachment portion 240. Any other suitable sheet can be included.

The material that cannot flow beyond the receiving surface 180 is shown to be widened (or mushroomed out) in a direction perpendicular to direction A to form a cap 247. In other words, the object 200 is printed on the first side of the attachment portion 240 and the bead material flows across the attachment portion 240 and is the second of the attachment portion 240 on the opposite side of the first side. Widen on the side of. In the bottom view in the z direction, the size (or area) of the cap 247 may be larger than the size (or area) of the opening 245. Thereby, the cap 247 can form a mechanical locking device that connects the attachment portion 240 to the object 200. Advantageously, the attachment portion 240 can be reliably bonded to the object 200 even if there is no or slight adhesion between the attachment portion 240 and the object 200.

With reference to FIG. 2C, the attachment portion 240 is shown to have an array of openings 245. The beads of object 200 are shown to be printed along a row of openings 245 and to form a row of caps 247. When the object 200 is printed to cover more openings 245, more caps 247 can be formed, further increasing the strength of the mechanical locking between the attachment portion 240 and the object 200. be able to.

FIG. 2C shows the x direction as if aligned (parallel) with respect to a row of openings 245 for illustration purposes only, but the x direction is not limited to a parallel row of openings 245. Alternatively, it may be oriented with respect to the column. FIG. 2C shows an array of openings 245, each with an ellipse, for illustration purposes only, but the attachment portion 240 has a uniform shape and / or a different shape and is arranged in any pattern of choice. It can have any number of openings 245 made.

With reference to FIG. 3, a typical flowchart of one embodiment of method 400 for forming structure 300 (shown in FIG. 2A) is shown. At 420, the attachment portion 240 can be selectively placed in the system 100. For example, the attachment portion 240 can be arranged so as to be in contact with the printing substrate 140 at least partially. Additional and / or alternative, the attachment portion 240 can be placed at a predetermined spacing from the printing substrate 140. In other words, the attachment portion 240 can be arranged without contacting the printing substrate 140.

At 430, the object 200 can be printed, at least partially, on the attachment portion 240. The object 200 can be attached to the attachment portion 240 during or after printing. The bond between the object 200 and the attachment portion 240 may be of any suitable nature. In one embodiment, the bond may include a chemical and / or physical bond, such as adhesion. Additional and / or alternative, the bond may include mechanical locking (eg, shown in FIG. 2B).

At 410, the attachment portion 240 can be selectively prepared. Preparing the attachment portion 240 involves one or more processes for processing the attachment portion 240 (pre-treating the surface of the attachment portion 240) to allow coupling between the attachment portion 240 and the object 200. Can include. In one example, the preparation can include performing a surface pretreatment to increase the roughness of the coupling surface 242 (shown in FIG. 2A). Additional and / or alternative, surface pretreatment can result in active chemical bonds on the bond surface 242. Typical surface treatments can include plasma treatment, sputtering, etching, UV ozone treatment, wet etching, chemical wiping, flame treatment, polishing and / or milling. In one embodiment, the base portion 243 (shown in FIG. 2A) can be formed from a material containing metals such as aluminum and / or steel. In one embodiment, the preparation comprises plasma treatment of the base portion 242 to clean the bond surface 242 to increase the surface energy of the bond surface 242 and / or roughen the bond surface 242 in order to improve the bond. be able to.

FIG. 3 shows the preparation at 410 and the placement at 420 as being performed prior to printing at 430 for illustrative purposes only, but the preparation at 410 and / or the placement at 420 is limited. It can be performed before and / or during printing at 430 without. Optionally, the method 400 can include fixing the attachment portion 240 to the object 200 after printing at 430. Advantageously, the separation of the attachment portion 240 from the object 200 can be further prevented.

With reference to FIG. 4A, the attachment portion 240 is shown as having a coupling layer 244 between the base portion 243 and the object 200. The binding layer 244 can be placed on the base portion 243 prior to printing the object 200 on the attachment portion 240. In a little different way, preparing the attachment portion 240 can include placing the bond layer 244 on the base portion 243, where the bond surface 242 is the boundary between the bond layer 244 and the object 200. It becomes a face. The bond between the bond layer 244 and the base portion 243 may be of any suitable property. In one embodiment, the bond may include a chemical and / or physical bond, such as adhesion. Additional and / or alternative, the bond may include mechanical locking (eg, shown in FIG. 4B). The bond layer 244 can bond the attachment portion 240 to the object 200 upon contact with and / or heating the object 200. For example, the bond layer 244 can absorb heat from the object 200 during printing and / or, for example, if the printing substrate 140 includes a table to be heated, it can absorb heat from the printing substrate 140. can.

A typical bond layer 244 can include an adhesive. For example, the adhesive can include woodworking bonds, contact adhesives, thermoplastic adhesives such as B-stage epoxy and thermosetting adhesives, or combinations thereof. A typical adhesive may be a resin base, a urethane base, an acrylate base, a butadiene-chloroprene base, an acrylic base, a neoprene base, a poly (vinyl alcohol) base, or a combination thereof. For example, the adhesive can include any contact adhesive, woodworking bond, or a combination thereof. Typical contact adhesives can include natural rubber and / or polychloroprene (or neoprene). In one example, the contact adhesive is 3M® 30NF Contact Adhesive (available from 3M Company in Maplewood, Minnesota, USA), 3M Fastbond® (registered from 3M Company). Trademarks) Pressure Sensitive Adhesive 4224 NF, Clear, (available from 3M Company) 3M® Fastbond® 30H Contact Adhesive, (available from 3M Company) 3M® Neoprene contact Adhesive 5, May include Neutral Sprayable. Typical woodworking bonds may be poly (vinyl alcohol) based or PVA based. In addition, the bond layer 244 can include acrylates, urethanes, epoxies, polyamides, polyimides and other hot melt adhesives. In one embodiment, an adhesive with lower adhesive strength, such as a contact adhesive or a woodworking bond, can be used to temporarily hold the object 200 during printing. In this embodiment, the panel can be pre-manufactured with alignment features. The panel can advantageously be aligned by the printed object, and further, the alignment feature for secondary alignment of fixtures, components, etc. after the object has been removed from the printed substrate. Can have. In some embodiments, the panel can be removed, for example, during vehicle inspection by unscrewing and stripping the weakly coupled panel.

In some embodiments, the selected layer 202 of the object 200 has become too cold, whether planned or unplanned (as a result of, for example, a power failure, material supply problem, etc.). If so, the adhesive can be applied to the cold selected layer 202 before the next layer 202 is printed. In a little different way, the base portion 243 can include one or more pre-printed layers 202, and the bonding layer 244 couples the newly printed layer 202 to the pre-printed layer 202. Adhesives can be included so that they can.

Additional and / or alternative, the bond layer 244 can include thermoplastic and / or thermosetting materials. A typical bond layer 244 can be formed from polyetherimide (PEI), polyethersulfone (PES), polycarbonate, ABS, polycarbonate, polyamide, PETG, PET, PPO, PPO, PPE, TPU or a combination thereof. can. In one embodiment, the bond layer 244 can be printed in 3D. In that case, a typical binding layer 244 can be formed from TPU and / or polyamide. In one embodiment, the bond layer 244 can be formed from polyamide at least in part. Typical polyamides capable of 3D printing can include Technomelt® available from Henkel AG & Co. KGaA in Dusseldorf, Germany.

FIG. 4A shows that the binding layer 244 is disposed throughout the base portion 243 for illustrative purposes only, although the binding layer 244 partially covers the base portion 243 without limitation. And / or can be completely covered. For example, the coupling layer 244 can be placed in a selected region on the base portion 243 where the base portion 243 joins the object 200.

The object 200 and the bond layer 244 can each be formed from any suitable material. In one example, the carbon fiber / ABS layer can be printed on an unfilled ABS sheet and permanent bonding occurs by raising the sheet temperature above a predetermined temperature (eg 110 ° C.). In another example, the PETG printed on the PETG sheet can be heated to create a permanent bond. Similar / similar materials have been described, but different materials can be used that interact preferably with or without heating. For example, PETG can be printed on an unfilled ABS sheet (eg, on the smooth side) at room temperature to create a permanent bond.

Optionally, the bond layer 244 can have a texture when viewed in the z direction. In other words, the bond layer 244 can have physical roughness to increase the grip force that improves the adhesion to the object 200. In one embodiment, the bond layer 244 can have a honeycomb pattern when viewed in the z direction. For example, the bond layer 244 can include a polycarbonate sheet with a honeycomb pattern (or honeycomb structure). In another example, the binding layer 244 can include PEI foam and / or PES foam with a foam texture. In one embodiment, the bond layer 244 can be secured to the base portion 243 in any suitable form, including using, for example, a selected adhesive.

With reference to FIG. 4B, the base portion 243 is shown to have a flat shape and to have a plurality of openings 249 (indicated by dashed lines) penetrating the base portion 243 in the z direction. The bond layer 244 is shown to be formed by printing a bead on the base portion 243. In the molten state, the bead material is pushed into the opening 249 in direction A until it contacts the receiving surface 180.

The material that cannot flow beyond the receiving surface 180 is shown to be widened (or mushroomed out) in a direction perpendicular to direction A to form a cap 246. In the bottom view in the z direction, the size (or area) of the cap 246 may be larger than the size (or area) of the opening 249. This allows the cap 246 to form a mechanical locking device that couples the coupling layer 244 to the base portion 243. Advantageously, the bond layer 244 can reliably bond to the base portion 243 even if there is no or slight adhesion between the bond layer 244 and the base portion 243.

With reference to FIG. 4C, the base portion 243 is shown to have an array of openings. The beads of the bond layer 244 are shown to be printed along a row of openings 249 and to form a row of caps 246. When the bond layer 244 is printed to cover more openings 249, more caps 246 can be formed, increasing the strength of the mechanical locking between the bond layer 244 and the base portion 243. It can be further enhanced.

FIG. 4C shows the x-direction so that it is aligned (parallel) to a row of openings 249 for illustrative purposes only, but the x-direction is not limited to that of the openings 249. It may be oriented with respect to rows or columns. FIG. 4C shows an array of openings 249, each with an ellipse, for illustrative purposes only, but the base portion 243 has, without limitation, a uniform shape and / or a different shape and is selected. It can have any number of openings 249 arranged in any pattern.

With reference to FIG. 5, a cross-sectional view of the structure 300 is shown. Of the structures 300, the object 200 is shown to include a first layer structure 210. The first layer structure 210 is shown to include one or more layers 202 stacked in the z direction. The first layer structure 210 can be manufactured using additive manufacturing.

The first layer structure 210 is shown to have side walls 214. The side wall 214 is shown to form a lateral angle A with respect to the x direction. In other words, the side wall 214 forms a lateral angle A with respect to the printing substrate 140.

With reference to FIG. 6, the attachment portion 240 is shown to be arranged at a distance d from the side wall 214. FIG. 6 shows that the attachment portion 240 and the first layer structure 210 are arranged on the printing substrate 140 for illustrative purposes only, but without limitation, the attachment portion 240 and The first layer structure 210 can be arranged on any uniform and / or different plane.

The attachment portion 240 is shown to provide a distal coupling surface 242 with respect to the printed substrate 140. The first layer structure 210 can include a bonding side 216 distal to the printing substrate 140. As shown exemplary in FIG. 6, the junction side 216 and the junction surface 242 may be coplanar.

The interval d may be the interval between any points on the first layer structure 210 and the attachment portion 240. As illustrated in FIG. 6, the spacing d may be the size of the gap 241 between the junction side 216 and the junction surface 242. In other words, the spacing d may be the spacing measured between the attachment portion 240 and the area of the first layer structure 210 where subsequent layers can be printed.

FIG. 6 shows that the gap 241 is uniform, for illustration purposes only. The gap 241 may be uniform and / or different at various positions along the side wall 214. For example, the side wall 214 can have a curved shape, an inclined shape and / or an irregular shape, resulting in a non-uniform gap 241 and a non-uniform spacing d along the side wall 214. In one example, the interval d may be zero and / or not zero at different positions. In other words, the side wall 214 may partially contact the attachment portion 240.

FIG. 6 shows that the first layer structure 210 and the attachment portion 240 have a gap 241 in the plane defined by the z and x directions, but the first layer structure 210 and the attachment portion 240 are limited. Without being done, they may be separated and / or in contact in the plane defined by the z and y directions and / or any other plane.

With reference to FIG. 7, it is shown that the second layer structure 220 is arranged on the attachment portion 240 and the first layer structure 210. The second layer structure 220 is shown to include one or more layers 202 stacked in the z direction. In one embodiment, the second layer structure 220 can be manufactured using the same addition manufacturing techniques as those of the first layer structure 210.

The second layer structure 220 is shown to span the gap 241. The interval d may be any suitable length. The small spacing d can advantageously reduce the possibility of deformation of the second layer structure 220 over the gap 241. The spacing d is due to the bridging capacity of the second layer structure 220, i.e., the ability of the material of the second layer structure 220 to overhang vertically without any support from the space below the second layer structure 220. Can be decided. In one embodiment, the interval d may be zero. Advantageously, the second layer structure 220 can be fully supported during printing to reduce or prevent deformation.

With reference to FIG. 8, a typical flowchart of an alternative embodiment of method 400 for forming structure 300 (shown in FIG. 7) is shown. At 432, the first layer structure 210 can be printed. At 434, the second layer structure 220 can be printed on the attachment portion 240 and the first layer structure 210. When printed, the second layer structure 220 can be coupled to the attachment portion 240. Advantageously, the attachment portion 240 can be replaced with the printed filler / support in the structure 300. Advantageously, the attachment portion 240 can provide the structure 300 with structural strength and / or any other properties of choice, secondary to attaching the attachment portion 240 to the second layer structure 220. Work can be eliminated.

At 420, the attachment portion 240 can be selectively placed in the system 100. The attachment portion 240 can be arranged from the first layer structure 210 at a selected interval d. FIG. 8 shows the selective arrangement at 420 as being performed before printing at 432 for illustration purposes only, but the arrangement at 420 is not limited and is after printing at 432. And / or can be done in between. In other words, the attachment portion 240 can be arranged after printing the first layer structure 210 and before printing the second layer structure 220. For example, the printing process may have a pause or time interval after printing the first layer structure 210 and before printing the second layer structure 220. The attachment portion 240 can be manually and / or mechanically assisted (eg by a robot) by the operator during the time interval. Advantageously, the attachment portion 240 can be arranged without interfering with the process of printing the first layer structure 210. Additionally and / or optionally, the attachment portion 240 can be placed before the printing of the first layer structure 210 is finished. The process of arranging the attachment portion 240 can be significantly shorter than the process of printing the first layer structure 210.

With reference to FIG. 9, the attachment portion 240 is shown attached to the support structure 248. In other words, the support structure 248 can support the attachment portion 240 so that the attachment portion 240 can be lifted from the printed substrate 140 by a selected height.

The support structure 248 can have any shape and size of choice. The support structure 248 can be formed using any suitable material and process. In one embodiment, the support structure 248 can be formed using 3D printing. Advantageously, 3D printing can form a support structure 248 with complex contours. Additional and / or alternative, the support structure 248 can be formed from a material that includes foam. The foam can be machined to obtain the selected size and shape. Advantageously, the support structure 248 can be formed inexpensively.

The attachment portion 240 can be secured in place with respect to the support structure 248 in any suitable form, including, for example, vacuuming, taping, tightening, bolting and / or application of removable adhesive. Additional and / or alternative, the attachment portion 240 can be anchored in place with respect to the support structure 248 via a mechanical connection, eg, a collaborative setback. In one embodiment, the attachment portion 240 can be temporarily attached to the support structure 248.

With reference to FIG. 10, the support structure 240 is shown removed from the attachment portion 240. The portion of the second layer structure 220 extending beyond the first layer structure 210 and the attachment portion 240 can form an overhang structure 224. The overhang structure 224 can maintain its shape before and / or after removal of the support structure 248. In other words, the overhang structure 224 does not deform or break from the second layer structure 220 under gravity, even if it is placed unsupported in space.

The support structure 248 can be removed from the attachment portion 240. Removing the support structure 248 from the attachment portion 240 can include separating the support structure 248 from direct contact with the attachment portion 240. The support structure 248 can be removed at any suitable time. In one embodiment, the second layer structure 220 can be cooled and / or solidified to room temperature before the support structure 248 is removed from the attachment portion 240. Advantageously, the support structure 248, in combination with the attachment portion 240, provides support to the second layer structure 220 during cooling and / or solidification to avoid deformation of the second layer structure 220. be able to. Upon completion of cooling and / or solidification, the second layer structure 220 is able to obtain sufficient structural strength and does not deform even after the support structure 248 has been removed.

With reference to FIG. 11, the first layer structure 210 is shown to include the first layer structures 210A, 210B. Each of the first layer structures 210A, 210B is shown to include one or more layers 202 stacked in the z direction. The first layer structures 210A, 210B can include a uniform number and / or a different number of layers 202. In one embodiment, the first layer structures 210A, 210B can include the same number of layers 202. Advantageously, the first layer structures 210A, 210B can be printed simultaneously, and the surfaces of the first layer structures 210A, 210B exposed to subsequent printing layers may be flat and / or coplanar. ..

FIG. 11 shows an attachment portion 240 arranged between the first layer structures 210A and 210B. The attachment portions 240 are shown to be at intervals d1 and d2 from the first layer structures 210A and 210B, respectively. The intervals d1 and d2 may be uniform and / or different. FIG. 11 shows the first layer structures 210A, 210B and the second layer structure 220 arranged on the attachment portion 240.

With reference to FIG. 12, the side wall 214 of the first layer structure 210 is shown as a plane tilted away from the z direction. In other words, the lateral angle A is not a right angle. FIG. 12 shows a side angle A smaller than 90 degrees.

The lateral angle A can have any suitable value. The minimum value of the lateral angle A can be determined by the material, printing process and / or aspect ratio. In one embodiment, the lateral angle A may be small if the bead (not shown) for printing the first layer structure 210 is wide. For example, if the bead has a large aspect ratio, the lateral angle A may be small. The aspect ratio can include the ratio of the width (or size in the y direction) to the height (or size in the z direction) of the bead. Additional and / or alternative, the lateral angle A may be small if there is a large solidification time between the layers 202. A typical side angle A may be 35 to 90 degrees.

With reference to FIG. 13, the side wall 214 of the first layer structure 210 is shown to include a curved surface tilted away from the z direction. The side wall 214 can have a plurality of lateral angles A at each position along the side wall 214. As shown in FIG. 13, the lateral angle A is shown to include a lateral angle A1 in the end region of the side wall 214 and a lateral angle A2 in the intermediate region of the side wall 214. The lateral angles A1 and A2 may be uniform and / or different.

The minimum value of each lateral angle A1 and A2 can be determined by the material, the printing process and / or the aspect ratio. In one embodiment, if the beads (not shown) for printing the first layer structure 210 are wide, the lateral angles A1 and A2 may be small. For example, if the bead has a large aspect ratio, the lateral angles A1 and A2 may be small. The aspect ratio can include the ratio of the width (or size in the y direction) to the height (size in the z direction) of the bead. Additional and / or alternative, the lateral angles A1 and A2 may be small if there is a large solidification time between the layers 202. Typical lateral angles A1 and A2 may be 35-90 degrees, respectively.

The side wall 214 is shown linearly in FIG. 12 and curved in FIG. 13 for illustration purposes only, but the side wall 214 may be linear or curved without limitation. It may be made to be made, or it may be a combination thereof.

With reference to FIG. 14, the coupling surface 242 is shown to be joined to the second layer structure 220. The form and / or shape of the coupling surface 242 can determine the second layer structure 220 printed on the attachment portion 240. FIG. 14 shows an inclination angle B existing between the bonding surface 242 and the printing substrate 140. Effectively, the overhang structure 224 formed on the attachment portion 240 can have a side wall forming an inclination angle B with respect to the printing substrate 140.

The tilt angle B may have any suitable value. In one embodiment, the tilt angle B can have values that make it difficult and / or impossible to achieve 3D printing without being supported by the attachment portion 240. A typical tilt angle B may be 0 degrees to 45 degrees or 0 degrees to 35 degrees. Advantageously, if the second layer structure 220 is formed from a material with limited overhanging ability, or formed using a process that allows limited overhanging, it is small without any support. If the value tilt angle B cannot be formed, the attachment portion 240 can provide support to achieve such a small tilt angle B.

In one embodiment, the tilt angle B may be zero. Therefore, the bonding surface 242 may be parallel to the printing substrate 140. For example, the bonding surface 242 may be coplanar with the bonding side 216 (shown in FIG. 6) of the first layer structure 210.

With reference to FIG. 15, the attachment portion 240 is shown to include an attachment portion 240A and an attachment portion 240B laminated on the attachment portion 240A. The attachment portion 240B is shown to have a coupling surface 242B distal to the coupling surface 242A of the attachment portion 240A with respect to the printing substrate 140. The object 200 is shown to include a second layer structure 220 and a third layer structure 230 formed on the attachment portion 240B. When printed, the second layer structure 220 can be coupled to the attachment portion 240A. Additional and / or alternative, the third layer structure 230 can be coupled to the attachment portion 240B when printed.

FIG. 15 shows the attachment portion 240B laminated on the attachment portion 240A, but without limitation, the attachment portion 240B may have any surface, such as a printed substrate 140 and / or any printed layer. Can be placed on top. For example, the attachment portion 240B can be placed on the support structure 248 (shown in FIG. 9) and the support structure 248 can be laminated on the attachment portion 240A. Optionally, the support structure 248 can be removed from the attachment portion 240B when the attachment portion 240B and the third layer structure 230 are coupled. Although FIG. 15 shows attachment portions 240A, 240B, any number of uniform and / or different attachment portions 240 can be used.

With reference to FIG. 16, a typical flowchart of one embodiment of method 400 for manufacturing structure 300 (shown in FIG. 15) is shown. Method 400 is shown to include further details of printing at 430. At 432, the first layer structure 210 can be printed. At 434, the second layer structure 220 can be printed on the first layer structure 210 and the attachment portion 240A. The attachment portion 240A can be coupled to the second layer structure 220. At 436, the third layer structure 230 can be printed on the second layer structure 220 and the attachment portion 240B. The attachment portion 240B can be coupled to the third layer structure 230.

In other words, as shown in 436, the object 200 (shown in FIG. 15) at a different height and / or spacing from the printed substrate 140 (shown in FIG. 15). Printing at 434 can be repeated by arranging additional attachment portions 240 for printing to form the plurality of overhang structures 224,234. Although it is shown in FIG. 16 that it is repeated only once, the printing in 434 can be repeated any number of times without limitation.

With reference to FIG. 17, a typical cross-sectional view of the structure 300 is shown. Of the structures 300, the object 200 is shown to include a first layer structure 210. The first layer structure 210 is shown to include a support member 212. The support member 212 may include a portion of one or more selected layers 202 of the first layer structure 210 adjacent to the side wall 214 or the peripheral region of the first layer structure 210. The support member 212 can be combined with the layer 202 of the first layer structure 210 adjacent to the support member 212 to form a recess 215 capable of at least partially accommodating the attachment portion 240. This allows the support member 212 to allow the attachment portion 240 to be located (and / or coupled in place) at a higher position, at least partially above the space. In other words, the support member 212 can be arranged on the first layer structure 210 without contacting the printing substrate 140. In some embodiments, an adhesive can be applied to the bottom and / or sides of the attachment portion 240, for example to bond to the object 200 at least temporarily within the recess 215.

The support member 212 can have any suitable shape. FIG. 17 shows the support member 212 as including a wall portion including a portion of one or more layers 202 proximal to the printed substrate 140. The attachment portion 240 can be placed in the end region of the wall portion distal to the printing substrate 140.

FIG. 17 shows two first layer structures 210A and 210B, respectively, including support members 212A and 212B, respectively, for illustration purposes only, where the object 200 is one first layer structure 210 or one or more. Can include a uniform and / or different first layer structure 210. Each first layer structure 210 may include, without limitation, one support member 212 or any number of uniform and / or different support members 212. FIG. 17 shows the first layer structures 210A, 210B, each in contact with the attachment portion 240 in the x direction, with any uniform and / or different spacing d (shown in FIG. 7) of x. It may be present between the first layer structure 210 and the attachment portion 240 in the direction and / or the y direction.

With reference to FIG. 18, the second layer structure 220 is shown to be located on the attachment portion 240 and the first layer structure 210. When printed, the second layer structure 220 can be coupled to the attachment portion 240. Advantageously, the second layer structure 220 can be supported during printing, and deformation of the second layer structure 220 due to the gap between the first layer structures 210A and 210B can be reduced or prevented. ..

Advantageously, the attachment portion 240 can be supported by the first layer structure 210, so that only any support (eg, support structure 248 (shown in FIG. 9)) is required at a minimum. The attachment portion 240 can be arranged. If a printed infill or other support structure between the attachment portion 240 and the printing substrate 140 is not desired, it is advantageous to eliminate the additional step of arranging and removing the support structure 248. .. The size of the attachment portion 240 in the z direction may be smaller than the size of the first layer structure 210 and need not be equal to the size of the first layer structure 210. Therefore, the size of the attachment portion 240 can be selected with greater flexibility.

With reference to FIG. 19, the support member 212 is shown to have a non-uniform side wall 214. In other words, the side wall 214 of the first layer structure 210 is shown to include a plane that is tilted away from the z direction and is not perpendicular to the printing substrate 140. In other words, the support member 212 may include one or more layers 202 overhanging the printed substrate 140 so as to form a shelf in the distal direction. Since the first layer structure 210 can further have a recess 215, the attachment portion 240 can be further supported by the support member 212.

FIG. 19 shows a portion of the side wall 214 deviating from the z direction for illustration purposes only, but without limitation, the side wall 214 may be partially and / or completely deviated from the z direction. .. FIG. 19 shows a side wall 214 containing a plurality of straight sections for illustration purposes only, but the side walls 214 are any number of, without limitation, straight and curved, respectively. Can include uniform and / or different sections of.

The disclosed embodiments further disclose structure 300 (shown in FIG. 2A) formed using additive manufacturing. The structure 300 can include an object 200 (shown in FIG. 2A) and an attachment portion 240 (shown in FIG. 2A) attached to the object 200. The disclosed embodiments further disclose the structure 300 shown in FIGS. 4, 7, 9, 10, 11, 11-15 and 17-19.

With reference to FIG. 20, a selective secondary coupling layer 262 is arranged and shown on the support member 212. A typical secondary bond layer 262 can be formed from an adhesive material. For example, the secondary bond layer 262 may be the same or similar to the various examples of bond layer 244 (shown in FIG. 4A) disclosed above. The attachment portion 240 can be attached to the support member 212 via the secondary coupling layer 262.

FIG. 20 shows the secondary bond layer 262 arranged at the bottom of the recess 215 parallel to the print substrate 140 for illustration purposes only, but the secondary bond layer 262 is the printed substrate 140. It can be provided on any surface of the recess 215 that is not parallel to. For example, the secondary bond layer 262 can be provided on the side surface of the attachment portion 240 which may be perpendicular to the printing substrate 140 and / or at any angle with respect to the printing substrate 140.

Additional and / or alternative, the second layer structure 220 is shown to include a fixing member 222. The fixing member 222 can include a part of one or more selected layers 202 of the second layer structure 220 formed on the edge region of the attachment portion 240. In other words, the fixing member 222 can include a peripheral region of a second layer structure 220 formed on the attachment portion 240. The fixing member 222 can capture the attachment portion 240 and prevent the attachment portion 240 from moving in the z direction. Advantageously, the attachment portion 240 can be fixed in place.

Additional and / or alternative, a plurality of second layer structures 220, including the second layer structures 220A-220C, are shown formed to partially cover the attachment portion 240. In other words, a gap 225 is provided between the second layer structures 220 adjacent to each other, whereby the plurality of second layer structures 220 continuously cross the attachment portion 240. Not connected. Advantageously, the second layer structure 220 does not necessarily bridge the two first layer structures 210, and the attachment portion 240 can allow for a variety of shapes of overhang structures.

21 to 24 show a cross-sectional view of the system 100 in the xz plane. The structure 300 (shown in FIG. 2) is alternative so that the cross section of the system 100 in the yz plane may be the same and / or similar to the cross section shown in FIGS. 21-24. Can be printed in format.

With reference to FIG. 21, the basic structure 260 is arranged and shown on the printing substrate 140. The foundation structure 260 can include any suitable structure. FIG. 21 shows a foundation structure 260 including one or more foundation layers 202A. In one embodiment, the base layer 202A can be printed in 3D. The selective secondary bond layer 262 is shown arranged in the foundation structure 260. The attachment portion 240 can be attached to the foundation structure 260 via the secondary bond layer 262.

As shown in FIG. 21, the foundation structure 260 may be an integral part of the object 200. In other words, the layer 202 of the object 200 can be laminated, at least partially, on the foundation structure 260. However, without limitation, the object 200 can be completely printed on the attachment portion 240 and separated from the foundation structure 260.

With reference to FIG. 22, a control system 500 for addition manufacturing is shown. The control system 500 can be configured to control the print head 120 (shown in FIG. 1). The control system 500 can include a processor 510. Processor 510 is one or more general purpose microprocessors (eg, single-core or multi-core processors), application-specific integrated circuits, application-specific instruction set processors, graphics processing units, physical processing units, digital signal processing units, coprocessors, etc. It can include network processing units, encryption processing units and the like.

Processor 510 can execute instructions to execute a computerized model of control system 500 and / or object 200 (shown in FIG. 2A). In one non-limiting example, the instructions include one or more additional manufacturing software programs. The program can be run to control the system 100, which includes multiple printing options, settings and techniques for performing additional printing of large components.

The program can include a computer-aided design (CAD) program for generating a 3D computer model of the object 200. Additional and / or alternatives, 3D computer models can be imported from another computer system (not shown). The 3D computer model may be an industry standard solid, surface or mesh file format.

The program can load a 3D computer model to print the object 200, generate a print model, and generate machine language to control the system 100. ^{A typical program can include LSAM Print 3D} available from Thermwood Corporation in Dale, Indiana. Additional and / or alternative, typical programs can include unfolder module software, bend simulation software, laser programming and / or nesting software available from Cincinnati Incorporated in Harrison, Ohio.

As shown in FIG. 22, the control system 500 may include one or more hardware components as needed. Typical additional hardware components include, but are not limited to, memory 520 (alternatively referred to herein as a non-transitory computer-readable medium). Typical memory 520s include, for example, random access memory (RAM), static RAM, dynamic RAM, read-only memory (ROM), programmable ROM, erasable programmable ROM, electrically erasable programmable ROM, flash memory. It can include secure digital (SD) cards and / or the like. Instructions for executing a computerized model of control system 500 and / or object 200 can be stored in memory 520 for execution by processor 510.

Additional and / or alternative, the control system 500 may include a communication module 530. The communication module 530 operates to exchange data and / or instructions between the control system 500 and another computer system (not shown) using any wired and / or wireless communication method. Hardware and software can be included. For example, the control system 500 can receive computer design data corresponding to the object 200 via the communication module 530. Typical communication methods can include, for example, wireless, wireless fidelity (Wi-Fi), cellular, satellite, broadcast or a combination thereof.

Additional and / or alternative, the control system 500 can include a display device 540. The display device 540 may include any device that operates to display programming instructions for operating the control system 500 and / or to display data about the printhead 120. Additional and / or alternative, the control system 500 may optionally include one or more input / output devices 550 (eg, buttons, keyboards, keypads, trackballs).

Processor 510, memory 520, communication module 530, display device 540 and / or input / output device 550 can be configured to communicate, for example, using hardware connectors and buses and / or in wireless form.

Various modifications and alternatives are possible in the disclosed embodiments, specific examples of which are shown in the drawings as examples and are described in detail herein. However, of course, the disclosed embodiments are not limited to the particular embodiments or methods disclosed, whereas the disclosed embodiments cover all modifications, equivalents and alternatives. ing.

Claims (41)

A method for additive manufacturing
Steps to place the attachment part on the printer,
A step of printing an object, at least in part, onto the attachment portion, wherein the attachment portion is said to be said by absorbing heat during the printing step, by locking to the object, or by a combination thereof. The steps to print, which are configured to bind to an object,
How to include. The method of claim 1, wherein the printer is part of a large-scale additive manufacturing system. The method according to claim 1 or 2, wherein the attachment portion is formed of a first material, and the object is formed of a second material different from the first material. The method according to any one of claims 1 to 3, wherein the arranging step includes at least a step of arranging the attachment portion formed of a thermoplastic material, a thermosetting material or a combination thereof. .. The method of claim 4, wherein the arranging step comprises arranging the attachment portion formed of a fiber reinforced thermoplastic material. The attachment portion comprises a perforated panel having one or more openings and arranged on a receiving surface, and the printing step is such that a portion of the object flows through the one or more openings. A claim comprising printing the object onto the attachment portion to form one or more caps that are widened by contact with the receiving surface and configured to lock onto the perforated panel. Item 1. The method according to any one of Items 1 to 5. 13. Method. The step to place is
A step of printing multiple layers that are stacked in the stacking direction and collectively form a closed loop,
A step of filling the space formed by the closed loop with a spray foam configured to expand in the space.
A step of cutting the expanded spray foam so as to be flat with the uppermost layer of the plurality of layers.
The method according to any one of claims 1 to 7, wherein the method comprises. The method according to any one of claims 1 to 8, further comprising a step of performing a surface treatment on the attachment portion before the printing step. The method according to claim 9, wherein the step to be carried out includes a step of carrying out plasma treatment on the attachment portion. The method according to claim 10, wherein the step to be carried out includes a step of carrying out plasma treatment on the attachment portion formed of metal. The method according to any one of claims 1 to 11, wherein the attachment portion is configured to bond to the object by absorbing heat from the object at least partially during the printing step. .. The base part and
With a bonding layer on the base portion that is joined to the object during the printing step,
The method according to any one of claims 1 to 12, further comprising a step of preparing the attachment portion comprising. The preparing step comprises placing the binding layer on the base portion, the binding layer said to the base portion by at least partially absorbing heat from the object during the printing step. 13. The method of claim 13, which is configured to be coupled to an object. 13. The method of claim 13 or 14, wherein the preparing step comprises placing the binding layer on the base portion, wherein the binding layer is at least partially formed of thermoplastic polyurethane. The method according to any one of claims 13 to 15, wherein the step to prepare includes a step of arranging the bonding layer on the base portion, and the bonding layer includes a sheet of a honeycomb pattern. The prepared step comprises placing the binding layer on the base portion, the binding layer comprising a sheet formed from polyethylene terephthalate glycol (PETG), polyethylene terephthalate (PET) or a combination thereof. The method according to any one of claims 13 to 16. The base portion comprises a perforated panel having one or more openings and disposed on the receiving surface.
The prepared step comprises printing the binding layer onto the base portion.
A portion of the binding layer flows through the one or more openings and forms one or more caps that are widened by contacting the receiving surface and are configured to lock onto the perforated panel. do,
The method according to any one of claims 13 to 17. The step to prepare is
A step of printing the base portion containing one or more layers by the printer.
The step of arranging the binding layer on the base portion and
The method according to any one of claims 13 to 18, which comprises. A step of printing a foundation structure containing one or more foundation layers,
The step of arranging the secondary bond layer on the foundation structure and
Including
The method according to any one of claims 1 to 19, wherein the arranging step includes a step of attaching the attachment portion to the foundation structure via the secondary bonding layer. The step of arranging includes any of claims 1 to 20, wherein the step of arranging includes a step of arranging an attachment portion including a flat panel, and the step of printing includes a step of printing the object as a whole on the flat panel. Or the method described in item 1. The printing step is
With the step of printing at least one first layer structure,
A step of printing a second layer structure on the first layer structure and the attachment portion after the placement step, wherein the attachment portion is configured to be coupled to the second layer structure. The steps to print and
The method according to any one of claims 1 to 21, comprising the method. 22. The method of claim 22, further comprising arranging the support structure on the printer, the step of arranging the attachment portion comprising arranging the attachment portion on the support structure. 23. The method of claim 23, further comprising removing the support structure from the attachment portion after the step of printing the second layer structure. 23 or 24. The method of claim 23 or 24, further comprising the step of preparing the support structure, which is at least partially formed from foam. The method according to any one of claims 23 to 25, further comprising printing the support structure using the printer. 22 to 26, wherein the printing step comprises printing the second layer structure, which is at least partially supported by the attachment portion, during the step of printing the second layer structure. The method according to any one item. The step of printing the at least one first layer structure includes the step of printing two first layer structures, and the attachment portion is arranged between the two first layer structures. The method according to any one of claims 22 to 27. The step of printing the second layer structure is the step of bridging the two first layer structures and printing the second layer structure, at least partially supported by the attachment portion. 28. The method of claim 28, comprising printing the layered structure of 2. The step of printing the two first layer structures is to provide a recess at a high position above the printing substrate of the printer to accommodate the attachment portion without contacting the printing substrate of the printer. 28 or 29. The method of claim 28 or 29, comprising printing the two first layered structures having. 30. Method. 30 or 31. The second layer structure includes at least one fixing member formed in the edge region of the attachment portion and configured to fix the attachment portion so as not to come out of the recess. The method of description. The method according to any one of claims 30 to 32, wherein the second layer structure does not extend continuously across the attachment portion. The method according to any one of claims 22 to 33, wherein there is a gap between the attachment portion and the at least one first layer structure. The step of printing the at least one first layer structure includes printing one or more first layers printed in the printing direction and laminated in the stacking direction.
Any of claims 22 to 34, wherein the step of printing the second layer structure comprises printing one or more second layers printed in the printing direction and laminated in the stacking direction. The method described in item 1. The step of printing the at least one first layer structure includes a step of printing the first layer structure having a side wall at a predetermined lateral angle with respect to the printing direction, and the lateral angle is. 35. The method of claim 35, which is 35 to 90 degrees. 36. The step of printing the first layer structure includes the step of printing the first layer structure having the side wall having the lateral angle changing along the side wall. Method. The step of printing the at least one first layer structure comprises printing the first layer structure having the curved side wall having the lateral angle decreasing along the stacking direction. The method of claim 36 or 37. The at least one first layer structure and the attachment portion each have a joint side proximal to the second layer structure, and the arranging step is described so that the joint side is coplanar. The method according to any one of claims 22 to 38, comprising the step of arranging the attachment portion. A structure formed at least partially by additive manufacturing,
An object containing one or more layers stacked in the stacking direction,
An attachment portion that is laminated with the object in the stacking direction and is coupled to the object by locking to or a combination thereof by absorbing heat generated during printing of the object.
Structure containing. The attachment portion comprises a perforated panel having one or more openings, and a portion of the object extends through the one or more openings and is configured to engage the perforated panel. 40. The structure of claim 40, which forms one or more caps.

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