A spatial acoustic wave manufacturing device, a 3D printing system and a printing method thereof

Abstract

This invention provides a spatial acoustic wave manufacturing device, including a frame, an acoustic wave generating module, and a control module. The frame is equipped with a first X-axis guide rail, a second X-axis guide rail, a first Y-axis guide rail, a second Y-axis guide rail, a rotary platform, a Z-axis stepping electric cylinder, a robotic arm, and an ultrasonic actuating head. The control module and the above structures form a multi-degree-of-freedom motion system. This device enables the liquid tank carrying the workpiece and the ultrasonic actuating head to perform precise, multi-axis linkage relative motion in space, allowing the acoustic wave focus to be accurately positioned and continuously moved in three-dimensional space. This enables non-contact processing of workpieces with complex curved surfaces such as overhangs, internal cavities, spiral flow channels, and honeycomb grids, and allows printing without any physical support materials.

Description

Technical Field

[0001] This invention pertains to ultrasonic 3D printing technology, specifically relating to a spatial acoustic wave manufacturing device, a 3D printing system, and a printing method thereof. Background Technology

[0002] Additive manufacturing (3D printing) technology enables the creation of physical parts and products from digital models. It's a process of directly converting computer-aided design into a physical entity. Compared to traditional manufacturing technologies, additive manufacturing utilizes bondable materials such as powdered metals, photosensitive resins, and plastics, creating complex shapes by layering materials. This results in high material utilization and shortens product development cycles. The technology has innovative applications in aerospace, military, medical, and automotive fields, enabling the production of lightweight, structurally optimized components. It represents a crucial development direction for advanced manufacturing and is an integral part of intelligent manufacturing.

[0003] Acoustic additive manufacturing is a technology that uses sound wave energy to manipulate the molding of thermosetting materials. Sound waves induce mechanical, physical, and chemical effects in the material, helping thermosetting resins or other materials to accumulate and solidify according to a predetermined path and shape. It offers advantages such as low cost, high manufacturing precision, and high manufacturing speed. While preliminary research has utilized the mechanical, physical, and chemical reactions of sound waves to achieve continuous interfacial manufacturing of homogeneous (heterogeneous) materials and has initially realized the control of complex shapes and properties of thermosetting materials, existing acoustic additive manufacturing technologies (such as W2023234771A1) directly mold solid objects, making it difficult to handle hollow structures or multi-material composites. Furthermore, using sound waves of a certain frequency with relatively low energy on the material to be processed still results in low processing efficiency. Summary of the Invention

[0004] To address the issues of low efficiency and difficulty in handling hollow structures or multi-material composites in existing ultrasonic printing technologies, this invention provides a spatial acoustic wave manufacturing device, a 3D printing system, and a printing method thereof.

[0005] To achieve the above objectives, the present invention provides the following technical solution: The present invention provides a spatial sound wave manufacturing device, including a frame, a sound wave generating module and a control module. A first X-axis guide rail and a second X-axis guide rail are horizontally installed inside the frame. A first Y-axis guide rail is vertically slidably connected to the top of the first X-axis guide rail. The first Y-axis guide rail can move along the first X-axis guide rail. A rotating platform is slidably connected to the top of the first Y-axis guide rail. The rotating platform can move along the first Y-axis guide rail and supports rotation from 0° to 360°. A liquid tank is provided on the rotating platform. Based on this, the rotating platform can drive the liquid tank to move arbitrarily within the range of 0° to 360°. The top of the second X-axis guide rail is vertically slidably connected to the second Y-axis guide rail, and the second Y-axis guide rail can move along the second X-axis guide rail. The bottom of the second Y-axis guide rail is slidably connected to the Z-axis stepping electric cylinder. The acoustic wave generating module includes a low-frequency component, a high-frequency component, and an ultrasonic actuating head. The ultrasonic actuating head is mounted on the bottom of the Z-axis stepping cylinder via a robotic arm. Based on this, the Z-axis stepping cylinder can drive the ultrasonic actuating head to move longitudinally. The low-frequency component and the high-frequency component are connected to the ultrasonic actuating head. The control module is communicatively connected to the first X-axis guide rail, the second X-axis guide rail, the first Y-axis guide rail, the second Y-axis guide rail, the rotary platform, the Z-axis stepping electric cylinder, the robotic arm, and the sound wave generating module.

[0006] Preferably, the control module further includes a sound pressure sensor and an optical camera. The sound pressure sensor is mounted on the frame and is used to detect the sound field data of the spatial sound wave manufacturing device. The optical camera is mounted on the frame and is used to observe the printing status of the workpiece.

[0007] Based on the sound field data detected by the sound pressure sensor and the workpiece porosity and material leveling state detected by the optical camera, the control module adjusts the working parameters of the first X-axis guide rail, the second X-axis guide rail, the first Y-axis guide rail, the second Y-axis guide rail, the rotary platform, the Z-axis stepping cylinder, the robotic arm, and the sound wave generating module to ensure that the sound waves output by the ultrasonic actuating head can accurately act on the composite printing material in the liquid tank. Meanwhile, by dynamically adjusting the processing orientation by rotating the rotating platform, and in conjunction with the linkage of the first X-axis guide rail, the second X-axis guide rail, the first Y-axis guide rail, the second Y-axis guide rail, and the Z-axis stepping electric cylinder, unsupported forming of complex curved surfaces such as spiral flow channels and honeycomb grids can be achieved.

[0008] Preferably, the vibration frequency of the sound wave output by the low-frequency component is 0.02 MHz to 0.1 MHz, and the vibration frequency of the sound wave output by the high-frequency component is 1 MHz to 5 MHz.

[0009] Preferably, the ultrasonic actuating head includes at least one of the following: annular, flat, spherical, conical, cylindrical, needle-shaped, trapezoidal, and custom-made irregular shapes. The spherical ultrasonic actuating head is suitable for making molds with hollow structures, the needle-shaped ultrasonic actuating head is suitable for making molds with thin-walled structures, and the annular ultrasonic actuating head is suitable for making molds with honeycomb structures.

[0010] Preferably, the liquid tank contains an ultrasonic coupling agent, which can reduce sound wave scattering, improve the concentration effect of sound waves, and thus improve printing efficiency.

[0011] To achieve the above objectives, the present invention also provides a 3D printing system, including a material supply module, a secondary curing module, and the aforementioned spatial acoustic wave manufacturing device, wherein the material supply module and the secondary curing module are communicatively connected to the control module; The material supply module includes a supply tank with a supply channel. An extrusion assembly is installed at the other end of the supply channel. The extrusion assembly can be connected to the liquid tank to supply material. The secondary curing module includes an acoustic chamber and a heating furnace. The acoustic chamber is equipped with an array of ultrasonic transducers, and the heating furnace is equipped with hot air nozzles.

[0012] To achieve the above objectives, the present invention also provides a 3D printing method applied to the aforementioned 3D printing system, comprising: A target model of the workpiece is constructed using a computer, and printing parameters are obtained through analysis. These printing parameters are then imported into the control module. The composite printing material is introduced into the liquid tank using the material supply module. The acoustic wave generating module is activated, and the acoustic wave is focused onto the composite printing material through the ultrasonic actuating head to solidify it, thereby obtaining the initial mold of the workpiece. Filler material is injected into the initial mold to obtain the filler of the workpiece. The filler can be selectively cured in an acoustic chamber, or subjected to gradient heating in a heating furnace, or the acoustic chamber and heating furnace can be processed in parallel to obtain the molded part of the workpiece.

[0013] Preferably, the composite printing material is prepared by mixing acoustic adhesive, metal or ceramic powder, and epoxy resin in a weight ratio of 1~15:70~90:1~15; The filler material includes at least one of metal paste, ceramic paste, and epoxy resin; The metal powder or metal slurry includes at least one of 316L stainless steel, 304L stainless steel, titanium alloy, aluminum alloy, cobalt-chromium alloy and tool steel. The ceramic powder or ceramic slurry includes at least one of Al2O3, ZrO2, SiO2, and SiC.

[0014] Preferably, activating the acoustic wave generating module and focusing the acoustic waves onto the composite printing material through the ultrasonic actuating head to solidify it includes: The control module adjusts the vibration frequency of the sound wave output from the sound wave generator module to 0.05 MHz~0.5 MHz, the output power to 50%~100%, and the energy density to 0.5 W / cm². 2 ~2 W / cm 2 ; Based on the sound field data detected in real time by the sound pressure sensor, the control module adjusts the working parameters of the first X-axis guide rail, the second X-axis guide rail, the first Y-axis guide rail, the second Y-axis guide rail, the rotary platform, the Z-axis stepping cylinder, the robotic arm, and the sound wave generating module so that the sound wave is focused on the composite printing material.

[0015] Preferably, a filler material is injected into the initial mold to obtain a filler for the workpiece. The filler is then placed in the acoustic chamber for curing, or placed in the heating furnace for gradient heating, or the filler is placed in the acoustic chamber for curing followed by gradient heating, including: The filling material is injected into the initial mold through the material supply module; The filler is placed in the acoustic chamber, and the vibration frequency of the ultrasonic transducer array is adjusted to 1 MHz~5 MHz, and the output power is 50%~100%, so that the focal domain of the ultrasonic transducer array is located at the interface of the filler material. The instantaneous energy generated by the cavitation effect of the acoustic wave induces the filler material to undergo a cross-linking reaction. During the reaction, the local temperature of the filler material rises to 70℃~3000℃, and the reaction continues for 20 min~50 min to solidify it and obtain the molded part. Alternatively, the filler is placed in a heating furnace and heated in a cycle at a rate of 5 ℃ / min~15 ℃ / min within the range of 50℃~200℃ for 20min~50min to solidify it and obtain a molded part; Alternatively, the filler is placed inside the acoustic chamber, and the vibration frequency of the ultrasonic transducer array is adjusted to 1 MHz~5 MHz, with an output power of 50%~100%, so that the focal region of the ultrasonic transducer array is located at the interface of the filler material. The instantaneous energy generated by the cavitation effect of the acoustic waves induces the filler material to undergo a cross-linking reaction. During the reaction, the local temperature of the filler material rises to 70℃~3000℃, and the reaction continues for 20 min~50 min to solidify it and obtain a preform. The preform is then placed in a heating furnace and cyclically heated at a rate of 5℃ / min~15℃ / min within the range of 50℃~200℃ for 20 min~50 min to obtain a molded part.

[0016] The present invention has the following beneficial technical effects: This invention provides a spatial acoustic wave manufacturing device. It comprises a multi-degree-of-freedom motion system consisting of a first X-axis guide rail, a second X-axis guide rail, a first Y-axis guide rail, a second Y-axis guide rail, a Z-axis stepping electric cylinder, and a rotating platform, and is communicatively connected to a control module. This device enables precise, multi-axis linkage relative motion between the liquid tank carrying the workpiece and the ultrasonic actuating head in space. This allows the acoustic wave focus to be precisely positioned and continuously moved in three-dimensional space, thereby achieving non-contact processing of workpieces with complex curved surfaces such as overhangs, internal cavities, spiral flow channels, and honeycomb grids.

[0017] The acoustic wave generator in this device includes a low-frequency component and a high-frequency component, capable of outputting acoustic waves with frequencies ranging from 0.02 MHz to 5 MHz. The low-frequency acoustic waves have a longer wavelength and strong penetrating power, enabling the curing of composite materials into structures with a certain thickness / height, such as overhangs, columns, and sheets, without the need for any physical support materials, greatly simplifying post-processing and reducing material waste. The high-frequency acoustic waves have a shorter wavelength and can be precisely focused to a very small point, forming a very high energy density, suitable for curing thin walls or fine features with high precision requirements. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of a 3D printing system according to an embodiment of this application; Figure 2 This is a schematic diagram of a spatial sound wave manufacturing apparatus according to an embodiment of this application; Figure 3 This is a partial schematic diagram of a spatial acoustic wave manufacturing apparatus according to an embodiment of this application; Figure 4 This is a schematic diagram of various types of ultrasonic action heads of a spatial sound wave manufacturing device according to an embodiment of this application; Figure 5 This is a schematic diagram of a heating furnace in a 3D printing system according to an embodiment of this application; Figure 6 This is a schematic diagram of the acoustic chamber of a 3D printing system according to an embodiment of this application; Figure 7 This is a flowchart of a 3D printing method according to an embodiment of this application; Figure 8 This is a schematic diagram of a hollow sample of a 3D printing method according to an embodiment of this application; Figure 9 This is a schematic diagram of a suspended structure sample of a 3D printing method according to an embodiment of this application.

[0019] 1. Frame; 11. Robotic arm; 12. First X-axis guide rail; 13. Second X-axis guide rail; 14. First Y-axis guide rail; 15. Second Y-axis guide rail; 16. Z-axis stepping electric cylinder; 17. Rotary platform; 18. Liquid tank; 2. Acoustic wave generation module; 21. Low-frequency component; 22. High-frequency component; 23. Ultrasonic actuating head; 3. Material supply module; 31. Supply tank; 32. Supply channel; 33. Extrusion component; 4. Secondary curing module; 41. Acoustic chamber; 411. Ultrasonic transducer array; 42. Heating furnace; 421. Hot air nozzle; 5. Control module; 51. Sound pressure sensor; 52. Optical camera; 6. Workpiece. Detailed Implementation

[0020] To better illustrate the technical solution of the present invention, the technical solution of the present invention will be clearly and completely described below in conjunction with the accompanying drawings and embodiments. The embodiments described below are only some embodiments of the present invention, and it should not be considered that the present invention has only the following implementation methods. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without making creative changes are within the protection scope of the present invention.

[0021] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0022] Example 1 This invention proposes a spatial sound wave manufacturing device, such as... Figure 1 and Figure 2 As shown, it includes a frame 1, a sound wave generating module 2 and a control module 5. A first X-axis guide rail 12 and a second X-axis guide rail 13 are horizontally installed inside the frame 1. A first Y-axis guide rail 14 is vertically slidably connected to the top of the first X-axis guide rail 12. The first Y-axis guide rail 14 can move along the first X-axis guide rail 12. A rotating platform 17 is slidably connected to the top of the first Y-axis guide rail 14. The rotating platform 17 can move along the first Y-axis guide rail 14 and supports rotation within 0°~360°. The rotating platform 17 is provided with the liquid tank 18, thereby enabling the liquid tank 18 to achieve multi-degree-of-freedom attitude adjustment.

[0023] The top of the second X-axis guide rail 13 is vertically slidably connected to the second Y-axis guide rail 15, and the second Y-axis guide rail 15 can move along the second X-axis guide rail 13. The bottom of the second Y-axis guide rail 15 is slidably connected to the Z-axis stepping electric cylinder 16. The sound wave generating module 2 includes a low-frequency component 21, a high-frequency component 22, and an ultrasonic actuating head 23. The ultrasonic actuating head 23 is mounted on the bottom of the Z-axis stepping cylinder 16 via a robotic arm 11. Based on this, the Z-axis stepping cylinder 16 can drive the ultrasonic actuating head 23 to move longitudinally. The low-frequency component 21 and the high-frequency component 22 are connected to the ultrasonic actuating head 23. The control module 5 is communicatively connected to the first X-axis guide rail 12, the second X-axis guide rail 13, the first Y-axis guide rail 14, the second Y-axis guide rail 15, the rotary platform 17, the Z-axis stepping electric cylinder 16, the robotic arm 11, and the sound wave generating module 2; In this embodiment, the control module 5 further includes a sound pressure sensor 51 and an optical camera 52. The sound pressure sensor 51 is mounted on the frame 1 and is used to detect the sound field data of the spatial sound wave manufacturing device. The optical camera 52 is mounted on the frame 1 and is used to detect the porosity and material leveling state of the workpiece 6.

[0024] It should be noted that in some application scenarios, based on the sound field data detected by the sound pressure sensor 51 and the porosity and material leveling state of the workpiece 6 detected by the optical camera 52, the control module 5 adjusts the working parameters of the first X-axis guide rail 12, the second X-axis guide rail 13, the first Y-axis guide rail 14, the second Y-axis guide rail 15, the rotary platform 17, the Z-axis stepping cylinder 16, the robotic arm 11, and the sound wave generating module 2 to ensure that the sound waves output by the ultrasonic actuating head 23 can be continuously and accurately focused on the composite printing material in the liquid tank 18.

[0025] Meanwhile, by rotating the rotating platform 17 to dynamically adjust the processing orientation, and in conjunction with the first X-axis guide rail 12, the second X-axis guide rail 13, the first Y-axis guide rail 14, the second Y-axis guide rail 15 and the Z-axis stepping electric cylinder 16, the unsupported forming of complex curved surfaces such as spiral flow channels and honeycomb grids can be achieved.

[0026] In this embodiment, the vibration frequency of the sound wave output by the low-frequency component 21 is 0.02 MHz to 0.1 MHz, and the vibration frequency of the sound wave output by the high-frequency component 22 is 1 MHz to 5 MHz.

[0027] like Figure 4 As shown, in this embodiment, the ultrasonic actuating head 23 includes at least one of the following shapes: annular, flat, spherical, conical, cylindrical, needle-shaped, trapezoidal, and custom-designed irregular shapes. Figure 4 'a' represents the annular ultrasonic ablation head. Figure 4 b is a flat ultrasonic ablation head. Figure 4 c represents a spherical ultrasonic ablation head. Figure 4d represents a cone-shaped ultrasonic actuation head. Figure 4 e represents a trapezoidal ultrasonic ablation head. Figure 4 f represents a needle-shaped ultrasonic treatment head; In some applications, different types of ultrasonic actuation heads can produce different effects. For example, spherical ultrasonic actuation heads are suitable for making molds with hollow structures, needle-shaped ultrasonic actuation heads are suitable for making molds with thin-walled structures, and annular ultrasonic actuation heads are suitable for making molds with honeycomb structures.

[0028] In this embodiment, the liquid tank 18 is provided with an ultrasonic coupling agent, which can reduce sound wave scattering, improve the concentration effect of sound waves, and thus improve printing efficiency.

[0029] Example 2 This invention also proposes a 3D printing system based on a spatial acoustic wave manufacturing device, such as... Figures 1-5 As shown, the 3D printing system also includes a material supply module 3 and a secondary curing module 4, which are communicatively connected to the control module 5. like Figure 1 As shown, the material supply module 3 includes a supply tank 31 for storing the composite printing material or filling material. The supply tank 31 is provided with a supply channel 32. An extrusion assembly 33 is installed at the other end of the supply channel 32. The extrusion assembly 33 can be connected to the liquid tank 18 to supply material. It should be noted that multiple supply slots 31 can be provided, and multiple supply channels 32 and extrusion components 33 can be provided accordingly to achieve independent supply and precise conveying of various materials.

[0030] like Figure 1 , Figure 4 and Figure 5 As shown, the secondary curing module 4 includes an acoustic chamber 41 and a heating furnace 42. The acoustic chamber 41 is equipped with an ultrasonic transducer array 411. A hot air nozzle 421 is installed at one end of the heating furnace 42.

[0031] Example 3 like Figure 6 As shown, the present invention also proposes a 3D printing method, applied to the 3D printing system proposed in Example 2, comprising: S1. Use a computer to build a target model and analyze and obtain printing parameters, and import the printing parameters into the control module 5.

[0032] It should be noted that in some application scenarios, computer modeling and design software is used to construct the target model, and CAM numerical control software is used to analyze the target model to obtain printing parameters and printing paths.

[0033] In this embodiment, the composite printing material is prepared by mixing acoustic adhesive, 316L stainless steel powder and epoxy resin in a weight ratio of 3:90:7.

[0034] S2. The composite printing material is introduced into the liquid tank 18 by the material supply module 3.

[0035] It should be noted that in some application scenarios, the composite printing material is placed in the supply tank 31 of the material supply module 3, transferred through the supply channel connected to the supply tank, and then precisely sprayed into the liquid tank by the extrusion component. At the same time, the required amount of composite printing material can be accurately sprayed based on the printing parameters imported from the control module 5.

[0036] S3. Start the sound wave generating module 2, and use the ultrasonic actuating head 23 to focus the sound wave onto the composite printing material to solidify it, thereby obtaining the initial mold of the workpiece 6.

[0037] In this embodiment, activating the acoustic wave generating module 2 and focusing the acoustic waves onto the composite printing material through the ultrasonic actuating head 23 to solidify it, thereby obtaining the initial mold of the workpiece 6, includes: The vibration frequency of the sound wave output by the sound wave generating module 2 is adjusted to 0.2 MHz, the output power to 80%, and the energy density to 1 W / cm² by the control module 5. 2 The ultrasonic actuating head 23 focuses the sound waves onto the composite printing material. During this process, the control module 5 dynamically adjusts the frequency, output power, and energy density of the sound waves output by the sound wave generating module 2 based on the sound field data detected in real time by the sound pressure sensor 51.

[0038] Based on the printing parameters imported into the control module 5, and simultaneously using the sound field data detected in real time by the sound pressure sensor 51 and the printing status of the workpiece 6 observed in real time by the optical camera 52, the control module 5 adjusts the working parameters of the first X-axis guide rail 12, the second X-axis guide rail 13, the first Y-axis guide rail 14, the first Y-axis guide rail 14, the rotary platform 17, the Z-axis stepping cylinder 16, and the robotic arm 11, and dynamically adjusts the position of the ultrasonic actuating head 23 and the liquid tank, so that the sound waves of the ultrasonic actuating head 23 are precisely focused on the composite printing material located in the liquid tank 18, thereby realizing the movement of the focal position of the sound waves in three-dimensional space according to the target model and printing parameters, and thus solidifying the composite printing material to obtain the initial mold of the workpiece 6.

[0039] It should be noted that in some application scenarios, the initial mold includes a hollow or porous geometric structure, and the workpiece 6 can be directly applied to the mold structure according to the application requirements, or a solid workpiece 6 can be obtained by filling material.

[0040] S4. Inject filling material into the initial mold to obtain the filler of workpiece 6. Place the filler in the acoustic chamber 41 for curing treatment, or place it in the heating furnace 42 for gradient heating treatment, or place the filler in the acoustic chamber 41 for curing treatment and then perform gradient heating treatment to obtain the molded part of workpiece 6.

[0041] In this embodiment, the step of injecting filler material into the initial mold to obtain the filler of workpiece 6, placing the filler in the acoustic chamber 41 for curing, or placing it in the heating furnace 42 for gradient heating, or placing the filler in the acoustic chamber 41 for curing and then performing gradient heating to obtain the molded part of workpiece 6, includes: The 316L stainless steel slurry is injected into the initial mold through the material supply module 3. It should be noted that in some application scenarios, 316L stainless steel slurry is placed in the supply tank 31 of the material supply module 3, and transported through the supply channel 32 connected to the supply tank 31. Then, it is precisely sprayed into the initial mold by the extrusion component 33. At the same time, the amount of 316L stainless steel slurry required is precisely controlled based on the printing parameters imported from the control module 5.

[0042] The filler is placed inside the acoustic chamber 41, and the vibration frequency of the ultrasonic transducer array 411 is adjusted to 2 MHz and the power is 80%, so that the focal zone of the ultrasonic transducer array 411 is located on the interface of the 316L stainless steel slurry, inducing a local temperature rise in the 316L stainless steel slurry. After reaching 1120°C, the temperature is maintained for 30 minutes to solidify the 316L stainless steel slurry and obtain a preform. The preform is placed in a heating furnace 42, and hot air is blown in through a hot air nozzle. It is heated in a cyclical manner within the range of 50°C to 200°C for 30 minutes at a rate of 5°C / min to remove the solvent and promote the cross-linking reaction of the acoustic adhesive, thereby obtaining the molded part.

[0043] In addition, as an optional subsequent process, the molded part can be immersed in a solution with a pH of 12 and a temperature of 60°C for 30 minutes to dissolve and remove the initial mold structure on its surface.

[0044] Example 4 like Figure 6 As shown, the present invention also provides a 3D printing method applied to the 3D printing system proposed in Embodiment 2, comprising: S1. Use a computer to build a target model and analyze and obtain printing parameters, and import the printing parameters into the control module 5.

[0045] In this embodiment, the composite printing material is prepared by mixing acoustic adhesive, Al2O3 powder and epoxy resin in a weight ratio of 3:90:7.

[0046] S2. The composite printing material is introduced into the liquid tank 18 by the material supply module 3.

[0047] S3. Start the sound wave generating module 2, and use the ultrasonic actuating head 23 to focus the sound wave onto the composite printing material to solidify it, thereby obtaining the initial mold of the workpiece 6.

[0048] In this embodiment, activating the acoustic wave generating module 2 and focusing the acoustic waves onto the composite printing material through the ultrasonic actuating head 23 to solidify it, thereby obtaining the initial mold of the workpiece 6, includes: The control module 5 adjusts the vibration frequency of the sound wave output by the sound wave generating module 2 to 0.05 MHz, the output power to 50%, and the energy density to 0.5 W / cm². 2 The ultrasonic actuating head 23 focuses the sound waves onto the composite printing material; during this process, the control module 5 dynamically adjusts the frequency, output power and energy density of the sound waves output by the sound wave generating module 2 based on the sound field data detected in real time by the sound pressure sensor 51.

[0049] Based on the printing parameters imported into the control module 5, and simultaneously using the sound field data detected in real time by the sound pressure sensor 51 and the printing status of the workpiece 6 observed in real time by the optical camera 52, the control module 5 adjusts the working parameters of the first X-axis guide rail 12, the second X-axis guide rail 13, the first Y-axis guide rail 14, the first Y-axis guide rail 14, the rotary platform 17, the Z-axis stepping cylinder 16, and the robotic arm 11, and dynamically adjusts the position of the ultrasonic actuating head 23 and the liquid tank, so that the sound waves of the ultrasonic actuating head 23 are precisely focused on the composite printing material located in the liquid tank 18, thereby realizing the movement of the focal position of the sound waves in three-dimensional space according to the target model and printing parameters, and thus solidifying the composite printing material to obtain the initial mold of the workpiece 6.

[0050] S4. Inject filling material into the initial mold to obtain the filler of workpiece 6. Place the filler in the acoustic chamber 41 for curing treatment, or place it in the heating furnace 42 for gradient heating treatment, or place the filler in the acoustic chamber 41 for curing treatment and then perform gradient heating treatment to obtain the molded part of workpiece 6.

[0051] In this embodiment, the step of injecting filler material into the initial mold to obtain the filler of workpiece 6, placing the filler in the acoustic chamber 41 for curing, or placing it in the heating furnace 42 for gradient heating, or placing the filler in the acoustic chamber 41 for curing and then performing gradient heating to obtain the molded part of workpiece 6, includes: The Al2O3 suspension is injected into the initial mold through the material supply module 3. The filler is placed inside the acoustic chamber 41, and the vibration frequency of the ultrasonic transducer array 411 is adjusted to 1 MHz and the power to 50%, so that the focal zone of the ultrasonic transducer array 411 is located at the interface of the Al2O3 suspension, inducing a local temperature rise in the Al2O3 suspension. After reaching 1640°C, the temperature is maintained for 30 minutes to solidify the Al2O3 suspension and obtain the molded part. The filler is placed inside the acoustic chamber 41. The vibration frequency of the ultrasonic transducer array 411 is adjusted to 1 MHz and the output power is 50%. The focal zone of the ultrasonic transducer array 411 is located at the interface of the Al2O3 suspension, inducing a local temperature rise in the Al2O3 suspension. After reaching 1640℃, the temperature is maintained for 30 minutes to solidify the Al2O3 suspension and obtain the molded part.

[0052] In addition, as an optional subsequent process, the molded part can be immersed in a solution with a pH of 12 and a temperature of 60°C for 30 minutes to dissolve and remove the initial mold structure on its surface.

[0053] Example 5 like Figure 6 As shown, the present invention also provides a 3D printing method applied to the 3D printing system proposed in Embodiment 2, comprising: S1. Use a computer to build a target model and analyze and obtain printing parameters, and import the printing parameters into the control module 5.

[0054] In this embodiment, the composite printing material is prepared by mixing acoustic adhesive, aluminum alloy powder and epoxy resin in a weight ratio of 3:90:7.

[0055] S2. The composite printing material is introduced into the liquid tank 18 by the material supply module 3.

[0056] S3. Start the sound wave generating module 2, and use the ultrasonic actuating head 23 to focus the sound wave onto the composite printing material to solidify it, thereby obtaining the initial mold of the workpiece 6.

[0057] In this embodiment, activating the acoustic wave generating module 2 and focusing the acoustic waves onto the composite printing material through the ultrasonic actuating head 23 to solidify it, thereby obtaining the initial mold of the workpiece 6, includes: The control module 5 adjusts the vibration frequency of the sound wave output from the sound wave generating module 2 to 0.5 MHz, the output power to 100%, and the energy density to 2 W / cm². 2 The ultrasonic actuating head 23 focuses the sound waves onto the composite printing material; during this process, the control module 5 dynamically adjusts the frequency, output power and energy density of the sound waves output by the sound wave generating module 2 based on the sound field data detected in real time by the sound pressure sensor 51.

[0058] Based on the printing parameters imported into the control module 5, and simultaneously using the sound field data detected in real time by the sound pressure sensor 51 and the printing status of the workpiece 6 observed in real time by the optical camera 52, the control module 5 adjusts the working parameters of the first X-axis guide rail 12, the second X-axis guide rail 13, the first Y-axis guide rail 14, the first Y-axis guide rail 14, the rotary platform 17, the Z-axis stepping cylinder 16, and the robotic arm 11, and dynamically adjusts the position of the ultrasonic actuating head 23 and the liquid tank, so that the sound waves of the ultrasonic actuating head 23 are precisely focused on the composite printing material located in the liquid tank 18, thereby realizing the movement of the focal position of the sound waves in three-dimensional space according to the target model and printing parameters, and thus solidifying the composite printing material to obtain the initial mold of the workpiece 6.

[0059] S4. Inject filling material into the initial mold to obtain the filler of workpiece 6. Place the filler in the acoustic chamber 41 for curing treatment, or place it in the heating furnace 42 for gradient heating treatment, or place the filler in the acoustic chamber 41 for curing treatment and then perform gradient heating treatment to obtain the molded part of workpiece 6.

[0060] In this embodiment, the step of injecting filler material into the initial mold to obtain the filler of workpiece 6, placing the filler in the acoustic chamber 41 for curing, or placing it in the heating furnace 42 for gradient heating, or placing the filler in the acoustic chamber 41 for curing and then performing gradient heating to obtain the molded part of workpiece 6, includes: The aluminum alloy slurry is injected into the initial mold through the material supply module 3; The filler is placed in a heating furnace 42, and hot air is blown in through a hot air nozzle. It is heated in a cyclical manner within the range of 50°C to 200°C at a rate of 15°C / min for 50 minutes to remove the solvent and promote the cross-linking reaction of the acoustic adhesive, thereby obtaining the molded part.

[0061] In addition, as an optional subsequent process, the molded part can be immersed in a solution with a pH of 12 and a temperature of 60°C for 30 minutes to dissolve and remove the initial mold structure on its surface.

Claims

1. A spatial sound wave manufacturing device, characterized in that, The system includes a frame (1), a sound wave generating module (2), and a control module (5). A first X-axis guide rail (12) and a second X-axis guide rail (13) are horizontally installed inside the frame (1). A first Y-axis guide rail (14) is vertically slidably connected to the top of the first X-axis guide rail (12). A rotating platform (17) is slidably connected to the top of the first Y-axis guide rail (14). A liquid tank (18) is provided on the rotating platform (17). A second Y-axis guide rail (15) is vertically slidably connected to the top of the second X-axis guide rail (13). A Z-axis stepping electric cylinder (16) is slidably connected to the bottom of the second Y-axis guide rail (15). The sound wave generating module (2) includes a low-frequency component (21), a high-frequency component (22) and an ultrasonic actuating head (23). The ultrasonic actuating head (23) is mounted on the bottom of the Z-axis stepping electric cylinder (16) via a robotic arm (11). The low-frequency component (21) and the high-frequency component (22) are connected to the ultrasonic actuating head (23). The control module (5) is communicatively connected to the first X-axis guide rail (12), the second X-axis guide rail (13), the first Y-axis guide rail (14), the second Y-axis guide rail (15), the rotary platform (17), the Z-axis stepper cylinder (16), the robotic arm (11), and the sound wave generating module (2).

2. The spatial acoustic wave manufacturing apparatus according to claim 1, characterized in that, The control module (5) also includes a sound pressure sensor (51) and an optical camera (52). The sound pressure sensor (51) is mounted on the frame (1) and is used to detect the sound field data of the spatial sound wave manufacturing device. The optical camera (52) is mounted on the frame (1) and is used to observe the printing status of the workpiece (6).

3. The spatial acoustic wave manufacturing apparatus according to claim 1, characterized in that, The vibration frequency of the sound wave output by the low-frequency component (21) is 0.02 MHz to 0.1 MHz, and the vibration frequency of the sound wave output by the high-frequency component (22) is 1 MHz to 5 MHz.

4. The spatial acoustic wave manufacturing apparatus according to claim 1, characterized in that, The ultrasonic actuating head (23) includes at least one of the following: annular, flat, spherical, conical, cylindrical, needle-shaped, trapezoidal, and custom-made irregular shapes.

5. The spatial acoustic wave manufacturing apparatus according to claim 1, characterized in that, The liquid tank (18) is equipped with an ultrasonic coupling agent.

6. A 3D printing system, characterized in that, It includes a material supply module (3), a secondary curing module (4), and a spatial acoustic wave manufacturing device according to any one of claims 1 to 5, wherein the material supply module (3) and the secondary curing module (4) are communicatively connected to the control module (5); The material supply module (3) includes a supply tank (31), the supply tank (31) is provided with a supply channel (32), and an extrusion assembly (33) is installed at the other end of the supply channel (32). The extrusion assembly (33) can be connected to the liquid tank (18) to supply materials. The secondary curing module (4) includes an acoustic chamber (41) and a heating furnace (42). The acoustic chamber (41) is equipped with an ultrasonic transducer array (411); the heating furnace (42) is equipped with a hot air nozzle (421).

7. A 3D printing method, characterized in that, Applied to the 3D printing system of claim 6, comprising: The target model of the workpiece (6) is constructed using a computer and the printing parameters are analyzed and obtained. The printing parameters are then imported into the control module (5). The composite printing material is introduced into the liquid tank (18) using the material supply module (3); The acoustic wave generating module (2) is activated, and the acoustic wave is focused on the composite printing material through the ultrasonic action head (23) to solidify it, thereby obtaining the initial mold of the workpiece (6); Filler material is injected into the initial mold to obtain the filler of the workpiece (6). The filler is placed in the acoustic chamber (41) for curing treatment, or placed in the heating furnace (42) for gradient heating treatment, or the filler is placed in the acoustic chamber (41) for curing treatment and then subjected to gradient heating treatment to obtain the molded part of the workpiece (6).

8. The 3D printing method according to claim 7, characterized in that, The composite printing material is prepared by mixing acoustic adhesive, metal or ceramic powder and epoxy resin in a weight ratio of 1~15:70~90:1~15. The filler material includes at least one of metal paste, ceramic paste, and epoxy resin; The metal powder or metal slurry includes at least one of 316L stainless steel, 304L stainless steel, titanium alloy, aluminum alloy, cobalt-chromium alloy and tool steel. The ceramic powder or ceramic slurry includes at least one of Al2O3, ZrO2, SiO2, and SiC.

9. The 3D printing method according to claim 7, characterized in that, The activation of the acoustic wave generating module (2) and the focusing of the acoustic wave onto the composite printing material via the ultrasonic actuating head (23) to solidify it include: The vibration frequency of the sound wave output by the sound wave generating module (2) is adjusted to 0.05 MHz~0.5 MHz by the control module (5), the output power is 50%~100%, and the energy density is 0.5 W / cm². 2 ~2 W / cm 2 ; Based on the sound field data detected in real time by the sound pressure sensor (51), the control module (5) adjusts the working parameters of the first X-axis guide rail (12), the second X-axis guide rail (13), the first Y-axis guide rail (14), the second Y-axis guide rail (15), the rotating platform (17), the Z-axis stepping cylinder (16), the robotic arm (11), and the sound wave generating module (2) so that the sound wave is focused on the composite printing material.

10. The 3D printing method according to claim 7, characterized in that, Filler material is injected into the initial mold to obtain the filler of workpiece (6). The filler is placed in the acoustic chamber (41) for curing, or placed in the heating furnace (42) for gradient heating, or the filler is placed in the acoustic chamber (41) for curing and then subjected to gradient heating, including: The filling material is injected into the initial mold through the material supply module (3); The filler is placed in the acoustic chamber (41), and the vibration frequency of the ultrasonic transducer array (411) is adjusted to 1 MHz~5 MHz, and the output power is 50%~100%, so that the focal domain of the ultrasonic transducer array (411) is located at the interface of the filler material. The instantaneous energy generated by the cavitation effect of the acoustic wave induces the filler material to produce a cross-linking reaction. During the reaction, the local temperature of the filler material rises to 70℃~3000℃, and the reaction continues for 20 min~50 min to solidify it and obtain the molded part. Alternatively, the filler is placed in a heating furnace (42) and heated in a cycle at a rate of 5 ℃ / min~15 ℃ / min within the range of 50℃~200℃ for 20min~50min to solidify it and obtain a molded part; Alternatively, the filler is placed in the acoustic chamber (41), and the vibration frequency of the ultrasonic transducer array (411) is adjusted to 1 MHz~5 MHz, and the output power is 50%~100%, so that the focal domain of the ultrasonic transducer array (411) is located at the interface of the filler material. The instantaneous energy generated by the cavitation effect of the acoustic wave induces the filler material to produce a cross-linking reaction. During the reaction, the local temperature of the filler material rises to 70℃~3000℃, and the reaction continues for 20 min~50 min to solidify it and obtain a preform. The preform is placed in a heating furnace (42) and heated in a cycle at a rate of 5 ℃ / min~15 ℃ / min in the range of 50℃~200℃ for 20 min~50 min to obtain a molded part.

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