A three-dimensional object manufactured using additive manufacturing technology and a manufacturing method thereof

Abstract

The present application discloses a three-dimensional object manufactured using additive manufacturing technology and a manufacturing method thereof. The three-dimensional object includes a cavity, the cavity including an inner surface and an outer surface, the inner surface and outer surface of the cavity being the inner surface and outer surface of the three-dimensional object. The three-dimensional object uses a support structure during the additive manufacturing process. After the support structure is removed, all contact points between the support structure and the three-dimensional object are located on the inner surface of the three-dimensional object.

Description

Technical Field

[0001] The present application relates to the field of 3D printing technology, and in particular to a three-dimensional object manufactured using additive manufacturing technology and a manufacturing method thereof. Background Art

[0002] The technical principle of 3D printing is to first divide a three-dimensional model into layers, then obtain the contour or image information of each layer, and then use a bondable material such as powdered metal or resin to complete the printed part through layer-by-layer printing. Because 3D printing solidifies the material layer by layer and stacks it up, the upper structure of the model generally requires support from the lower layer to prevent the printed part from deforming due to gravity during the printing process. However, if certain parts of the printed part are suspended, a support structure must be designed to complete the printing process together with the printed part to support the suspended parts. After 3D printing is completed, the support structure needs to be removed from the printed part. This process is often completed manually and is inefficient. In addition, in existing technologies, after the support structure is removed from the printed part, the contact points of the support structure remaining on the surface of the printed part will affect the appearance of the printed part and may even affect its normal use. Summary of the Invention

[0003] One of the embodiments of the present application provides a three-dimensional object manufactured using additive manufacturing technology, wherein the three-dimensional object includes a cavity, the cavity includes an inner surface and an outer surface, and the inner surface and outer surface are the inner surface and outer surface of the three-dimensional object; the three-dimensional object uses a support structure during the additive manufacturing process, and after the support structure is removed, all contact points between the support structure and the three-dimensional object are located on the inner surface of the three-dimensional object.

[0004] In some embodiments, the three-dimensional object uses a flipped digital model of the three-dimensional object during the additive manufacturing process. The flipped digital model is obtained by flipping the digital model of the three-dimensional object with respect to the cavity and exchanging the inner and outer surfaces.

[0005] In some embodiments, the flipped digital model of the three-dimensional object has the same structure as the digital model of the three-dimensional object before flipping.

[0006] In some embodiments, a support structure used in an additive manufacturing process of the three-dimensional object is connected to an outer surface of the flipped digital model of the three-dimensional object.

[0007] In some embodiments, the three-dimensional object is a sleeve.

[0008] In some embodiments, the three-dimensional object is a shoe cover or a sock cover.

[0009] One of the embodiments of the present application also provides a method for preparing a three-dimensional object using additive manufacturing technology, wherein the three-dimensional object includes a cavity, the cavity includes an inner surface and an outer surface, and the inner surface and outer surface are the inner surface and outer surface of the three-dimensional object. The method includes: (a) obtaining a flipped digital model of the three-dimensional object, wherein the flipped digital model is obtained by flipping the digital model of the three-dimensional object about the cavity, and the inner and outer surfaces are exchanged with each other; (b) adding a support structure to the flipped digital model to obtain a printed model, and the support structure is connected to the outer surface of the flipped digital model of the three-dimensional object; (c) using additive manufacturing technology to print the printed model to obtain a printed part containing the support structure; (d) removing the support structure on the printed part; and (e) flipping the cavity of the printed part so that the inner and outer surfaces are exchanged to obtain the three-dimensional object to be prepared. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The present application will be further described in the form of exemplary embodiments, which will be described in detail with reference to the accompanying drawings. These embodiments are not limiting, and in these embodiments, like numbers represent like structures, wherein:

[0011] Figure 1 is a schematic diagram of a digital model of a casing according to some embodiments of the present application;

[0012] Figure 2a yes Figure 1 A schematic diagram of a flipped digital model of the casing is shown;

[0013] Figure 2b yes Figure 1 The digital model of the casing shown is flipped to obtain Figure 2a Schematic diagram of the process of flipping a digital model shown;

[0014] Figure 3 yes Figure 2a Schematic diagram of a printed model obtained by adding support structures to a flipped digital model;

[0015] Figure 4 It is a flow chart of a method for preparing a three-dimensional object according to some embodiments of the present application.

[0016] Explanation of the accompanying drawings: 100 is the digital model of the casing; 110 is the cavity; 120 is the inner surface of the cavity; 130 is the outer surface of the cavity; 140 is the cavity opening; 200 is the flipped digital model of the casing; 210 is the cavity; 220 is the inner surface of the cavity; 230 is the outer surface of the cavity; 240 is the support structure; 250 is the contact point; 300 is the printing model of the casing; 400 is the method flow for preparing a three-dimensional object. DETAILED DESCRIPTION

[0017] To more clearly illustrate the technical solutions of the embodiments of this application, the following is a brief introduction to the drawings required for describing the embodiments. Obviously, the drawings described below are merely examples or embodiments of this application. Those skilled in the art can apply this application to other similar scenarios based on these drawings without inventive effort. Unless otherwise apparent from the context or otherwise noted, the same reference numerals in the figures represent the same structure or operation.

[0018] It should be understood that the terms "system," "device," "unit," and / or "module" used herein are a method for distinguishing different components, elements, parts, portions, or assemblies at different levels. However, if other terms can achieve the same purpose, the terms may be replaced by other expressions.

[0019] As used in this application and the claims, unless the context clearly indicates otherwise, the words "a," "an," "an," and / or "the" are not intended to refer to the singular but may include the plural. Generally speaking, the terms "comprises" and "include" only indicate the inclusion of the steps and elements specifically identified, and these steps and elements do not constitute an exclusive list. A method or apparatus may also include other steps or elements.

[0020] Flowcharts are used in this application to illustrate the operations performed by the systems according to the embodiments of the present application. It should be understood that the preceding or following operations are not necessarily performed in exact order. Instead, the steps may be processed in reverse order or simultaneously. Furthermore, other operations may be added to these processes, or one or more operations may be removed from these processes.

[0021] During 3D printing, to prevent deformation of the printed part due to gravity, a support structure is typically required to support the printed part. If certain parts of the printed part are suspended, a support structure must be designed to support the suspended portion of the printed part during printing. The support structure can be designed based on the printed part and 3D printed along with it. After 3D printing is complete, the support structure must be removed from the printed part. In the prior art, after the support structure is removed from the printed part, the remaining contact points of the support structure on the surface of the printed part can affect the appearance of the printed part and potentially hinder its proper use. While designing a support structure with smaller contact points makes it easier to remove and leaves less traces on the printed part, these smaller contact points may prevent the support structure from effectively supporting the printed part during printing, leading to print failure. Larger and / or more contact points, while effectively increasing the security of the support structure, can also leave larger and / or more traces, affecting the appearance and even the use of the printed part.

[0022] The embodiment of the present application provides a method for manufacturing a three-dimensional object using additive manufacturing technology, which solves the problem that the contact points of the support structure of a 3D printed object affect the appearance and use of the printed part. The method can be applied to 3D printing technologies such as photocuring, fused deposition modeling and three-dimensional powder bonding. The present application also relates to a 3D printed object obtained using this method, which can be used in various fields such as medicine, industry, life and art. Those skilled in the art can obtain, use and / or modify the digital model of the printed object on software such as Rhino, Solidworks, Catia or UG, and complete the printing through various 3D printing devices. The present application does not limit the 3D printed object and its application scenarios.

[0023] In some embodiments, additive manufacturing technology is used to manufacture a three-dimensional object having a cavity, wherein the cavity has an inner surface and an outer surface, and the inner and outer surfaces of the cavity serve as the inner and outer surfaces of the three-dimensional object. During the additive manufacturing process, this three-dimensional object requires the addition of a support structure due to structural and printing process requirements. After printing, the print can first undergo post-processing steps such as cleaning and post-curing, and then the support structure is removed. In the prior art, after the support structure is removed, contact points between the support structure and the print remain on the outer surface of the print, affecting its appearance and even its performance. Therefore, in the prior art, after the support structure is removed from the 3D print, the outer surface of the print must be polished, which is time-consuming and labor-intensive, increasing production costs. The method disclosed in the present invention first processes a digital model of the three-dimensional object to be printed, flips the cavity contained therein, and swaps the inner and outer surfaces of the cavity, thereby obtaining a flipped digital model of the original three-dimensional object digital model. That is, the inner surface of the original digital model becomes the outer surface of the flipped digital model, and the inner surface of the original digital model becomes the outer surface of the flipped digital model. Support structures are then added to the acquired flipped digital model as needed to produce a printed model. In the printed model, the support structures are connected to the outer surface of the flipped digital model. The printed model is then printed using a suitable additive manufacturing method to produce a printed part containing the support structures. Depending on the material and component requirements, the printed part containing the support structures may undergo post-processing steps such as cleaning and post-curing, followed by the removal of the support structures. After the support structures are removed, the contact points between the support structures and the printed part are now located on the outer surface of the printed part. The printed part's cavity is then flipped, meaning the inner surface of the cavity is turned out, swapping the inner and outer surfaces to produce the desired three-dimensional object. After the cavity flips, the contact points between the support structures and the printed part are now located on the inner surface of the three-dimensional object, while the outer surface remains smooth due to the lack of contact points with the support structures. This method simplifies processes such as polishing and grinding the outer surface of the printed part, saving manpower and resources and reducing production costs. Furthermore, due to the simplified post-processing steps, the support structure design step can consider increasing the density, number, and cross-sectional area of ​​the support structure contact points, thereby improving the success rate of the printing process.

[0024] Figure 1 Schematic diagram of a digital model of a casing according to some embodiments of the present application. Figure 1As shown, the casing 100 may include a cavity 110, and the cavity 110 includes an inner surface 120, an outer surface 130, and an opening 140. The inner surface 120 and the outer surface 130 are the inner and outer surfaces of the casing 100. If the cavity 110 of the casing 100 is turned over from its opening 140, that is, the inner surface 120 is turned out from the opening 140, the casing 100 is turned over. At this time, the inner surface 120 of the original casing is the outer surface of the turned over state, and the outer surface 130 of the original casing is the inner surface of the turned over state.

[0025] In some embodiments, the three-dimensional object manufactured using the additive manufacturing method disclosed in the present invention can be a cover, such as a shoe cover, a sock cover, etc.; in other embodiments, the three-dimensional object manufactured using the additive manufacturing method disclosed in the present invention can be a container.

[0026] Figure 2a is based on Figure 1 The flipped digital model 200 is formed by flipping the housing digital model 100. The flipped digital model 200 includes a cavity 210, which includes an inner surface 220 and an outer surface 230. The inner surface 120 of the original digital model is the outer surface 230 of the flipped digital model 200, and the outer surface 130 of the original digital model is the inner surface 220 of the flipped digital model 200. Figure 2b Schematic diagram of the process of flipping the digital model 100 of the housing. In some embodiments, the digital model 100 and its flipped digital model 200 have the same structure; in other embodiments, the digital model 100 and its flipped digital model 200 have different structures, for example Figure 1 The casing digital model 100 and its flipped digital model 200 shown in the figure have different structures. The connecting columns 121 of the hollow lattice on the inner surface 120 of the casing digital model 100 are thinner than the connecting columns 131 of the hollow lattice on its outer surface 130. Therefore, after flipping the digital model 100 about its cavity 110, the connecting columns 131 of the hollow lattice on the inner surface 220 of the flipped digital model 200 are thicker than the connecting columns 121 of the hollow lattice on its outer surface 230. The flipped digital model can be automatically generated using software algorithms (such as Rhino, SolidWorks, Catia, or UG), or it can be manually designed and adjusted.

[0027] Figure 3 yes Figure 2aThe printed model 300 is obtained by adding a support structure 240 to the digital flip model 200 shown in FIG. The support structure 240 is connected to the outer surface 230 of the digital flip model 200 through a plurality of contact points 250. The design and construction of the support structure 240 can be completed automatically by a software algorithm (such as Rhino, Solidworks, Catia or UG), or can be designed and adjusted manually. In some embodiments, the support structure can be a columnar, sheet-like or mesh structure. In some embodiments, the cross-sectional area of ​​the contact point 250 can be smaller than the cross-sectional area of ​​the support structure itself, thereby facilitating the removal of the support structure from the printed part.

[0028] After obtaining the print model 300, the model can be manufactured using additive manufacturing equipment to produce a printed part. The equipment can be a photo-curing 3D printer, a fused deposition model 3D printer, or a powder bonding 3D printer, etc., and the present invention does not impose any restrictions. After the printed part is manufactured, the support structure is removed after a series of post-processing steps. The post-processing steps may include but are not limited to cleaning (to remove excess uncured resin on the surface of the printed part), post-curing (which may include photo-curing, thermal curing, and / or moisture curing), etc. After the support structure is removed, the cavity of the printed part is flipped over, and its inner surface is turned out through the cavity opening, thereby exchanging the inner and outer surfaces. At this time, the support structure contact points 250 left on the surface of the printed part after the support structure is removed are transferred from the outer surface of the printed part to its inner surface, thereby preventing the residual traces of the support structure contact points 250 from affecting the appearance of the printed part. In some embodiments, before the printed part cavity is flipped, the support structure contact points 250 can be first processed, such as polishing or grinding, and then the cavity flipping is performed.

[0029] This application also provides a method for preparing a three-dimensional object using additive manufacturing technology, which uses a method for processing the residual support structure contact points on the surface of the printed part during the additive manufacturing process. Figures 1 to 3 The digital model shown is used for additive manufacturing of three-dimensional objects. Figure 4 FIG. 1 is a flow chart of a method for preparing a three-dimensional object according to some embodiments of the present application. Figure 4 As shown, the method 400 for preparing a three-dimensional object using additive manufacturing technology may include the following steps:

[0030] Step 410: Obtain a flipped digital model 200 of the three-dimensional object. The three-dimensional object includes a cavity 110 having an inner surface 120 and an outer surface 130, which are the inner and outer surfaces of the three-dimensional object. The flipped digital model 200 of the three-dimensional object is obtained by flipping the cavity of the digital model 100 of the three-dimensional object, swapping the inner and outer surfaces. In some implementations, the flipped digital model 200 of the three-dimensional object has the same structure as the pre-flipped digital model 100 of the three-dimensional object. In these embodiments, obtaining the flipped digital model 200 of the three-dimensional object is equivalent to obtaining the digital model 100 of the three-dimensional object, as the flipped digital model has the same structure as the flipped digital model. In other embodiments, obtaining the flipped digital model 200 of the three-dimensional object requires first obtaining the digital model 100 of the three-dimensional object, and then processing the digital model 100 to obtain the flipped digital model 200. The acquisition of the flipped digital model can be automatically completed through software algorithms (such as Rhino, Solidworks, Catia or UG), or can be designed and adjusted manually.

[0031] In step 420, a support structure 240 is added to the flipped digital model 200 of the three-dimensional object obtained in step 410 to produce a printed model 300. The support structure 240 is connected to the outer surface 230 of the flipped digital model 200 of the three-dimensional object, and all contact points 250 between the support structure 240 and the printed model 300 are located on the outer surface 230 of the flipped digital model 200. The design and construction of the support structure 240 can be performed automatically using software algorithms (such as Rhino, SolidWorks, Catia, or UG), or can be designed and adjusted manually. In some embodiments, the support structure 240 can be a columnar, sheet-like, or mesh-like structure. In some embodiments, the cross-sectional area of ​​the contact points 250 can be smaller than the cross-sectional area of ​​the support structure 240 itself, thereby facilitating removal of the support structure 240 from the printed part.

[0032] In step 430, the printed model obtained in step 420 is printed using an additive manufacturing device to obtain a printed part including the support structure 240. The additive manufacturing device can be a photo-curing 3D printer, a fused deposition model 3D printer, or a powder bonding 3D printer, etc., and the present invention does not impose any restrictions. In some embodiments, the materials that can be used in the photo-curing 3D printing method of three-dimensional objects disclosed in the present invention can include, but are not limited to, acrylates, methacrylates, olefins, N-vinyls, acrylamides, methacrylamides, styrenes, epoxy groups, thiols, 1,3-dienes, halogenated vinyls, acrylonitrile, vinyl esters, maleimides, vinyl ethers, olefins (such as methoxyethylene, 4-methoxystyrene, styrene, 2-methylprop-1-ene, 1,3-butadiene, etc.), vinyl ethers, N-vinylcarbazoles, lactones, lactams, cyclic ethers (e.g., epoxides), cyclic acetals, cyclosiloxanes, and oligomers and / or prepolymers containing one or more of the foregoing monomers. In some embodiments, the material that can be used in the photocuring 3D printing method for three-dimensional objects disclosed in the present invention can be a resin material with multiple curing mechanisms, such as the resin materials with dual-component dual-curing mechanisms disclosed in U.S. Patents US 9,598,606, US 9,453,142, US 9,982,164, US 9,676,963, and US10,155,882, the disclosures of which are incorporated herein by reference. For example, the resin material with dual-component dual-curing mechanisms disclosed in PCT / CN2020 / 095715, the disclosures of which are incorporated herein by reference. In some embodiments, the material used in the photocuring 3D printing method for three-dimensional objects disclosed in the present invention is an elastic resin material, the elastic modulus of which can be: 1-50 MPa, the tensile strength can be: 5-50 MPa, and the elongation at break can be: 50-600%.

[0033] Step 440: Remove the support structures from the printed part. Before removing the support structures, the printed part may undergo post-processing. This post-processing may include, but is not limited to, cleaning to remove excess uncured resin from the printed part's surface, post-curing (which may include light curing, heat curing, and / or moisture curing), etc. At this point, the support structure contact points remaining after the support structures are removed are located on the outer surface of the printed part. In some embodiments, the support structure contact points on the outer surface of the printed part may be processed, such as polishing or grinding.

[0034] In step 450, the cavity of the printed part, after the support structure has been removed, is flipped over, the inner surface of the cavity exposed, and the inner and outer surfaces are swapped to obtain the desired three-dimensional object. At this point, all contact points between the support structure and the printed part are located on the inner surface of the printed three-dimensional object. The outer surface, free from support structure contact points, remains smooth.

[0035] The method for processing the contact points of the support structure of a 3D printed object according to the embodiment of the present application may bring about beneficial effects including but not limited to: (1) after the support structure is removed, the contact points between the support structure and the prepared three-dimensional object are all located on the inner surface of the three-dimensional object, and the outer surface of the three-dimensional object has no support structure contact points, remaining smooth. This eliminates the need for post-processing steps such as polishing and grinding the outer surface of the three-dimensional object, saving manpower and material resources and reducing production costs; (2) when designing the support structure of the printed model, more support structures and / or more firmly connected support structure contact points can be designed, thereby increasing the success rate of the printing process.

[0036] The basic concepts have been described above. It will be apparent to those skilled in the art that the detailed disclosure above is merely illustrative and does not limit the present application. Although not explicitly stated herein, those skilled in the art may make various modifications, improvements, and amendments to the present application. Such modifications, improvements, and amendments are suggested in the present application and remain within the spirit and scope of the exemplary embodiments of the present application.

[0037] At the same time, this application uses specific terms to describe the embodiments of this application. For example, "one embodiment," "an embodiment," and / or "some embodiments" refer to a certain feature, structure, or characteristic related to at least one embodiment of this application. Therefore, it should be emphasized and noted that "one embodiment," "an embodiment," or "an alternative embodiment" mentioned twice or multiple times in different locations in this specification does not necessarily refer to the same embodiment. In addition, certain features, structures, or characteristics in one or more embodiments of this application may be appropriately combined.

[0038] In addition, unless expressly stated in the claims, the order of the processing elements and sequences described in this application, the use of alphanumeric characters, or the use of other names are not intended to limit the order of the processes and methods of this application. Although the above disclosure discusses some of the invention embodiments currently considered useful through various examples, it should be understood that such details are only for illustrative purposes, and the attached claims are not limited to the disclosed embodiments. On the contrary, the claims are intended to cover all modifications and equivalent combinations that are consistent with the essence and scope of the embodiments of this application. For example, although the system components described above can be implemented by hardware devices, they can also be implemented only by software solutions, such as installing the described system on an existing server or mobile device.

[0039] Similarly, it should be noted that, in order to simplify the presentation of this application and thus facilitate understanding of one or more embodiments of the invention, the foregoing descriptions of the embodiments of this application sometimes combine multiple features into a single embodiment, figure, or description thereof. However, this disclosure method does not mean that the subject matter of this application requires more features than those recited in the claims. In fact, an embodiment may have fewer features than all of the features of a single embodiment disclosed above.

[0040] In some embodiments, numbers are used to describe the quantity of components and attributes. It should be understood that such numbers used in the description of the embodiments are modified by the modifiers "about", "approximately" or "substantially" in some examples. Unless otherwise stated, "about", "approximately" or "substantially" indicate that the numbers are allowed to vary by ±20%. Accordingly, in some embodiments, the numerical parameters used in the description and claims are approximate values, which may change according to the required features of individual embodiments. In some embodiments, the numerical parameters should take into account the specified significant digits and adopt the general method of retaining digits. Although the numerical domains and parameters used to confirm the breadth of their range in some embodiments of the present application are approximate values, in specific embodiments, the settings of such numerical values ​​are as accurate as possible within the feasible range.

[0041] Each patent, patent application, patent application disclosure, and other materials, such as articles, books, specifications, publications, documents, etc., cited in this application is hereby incorporated by reference in its entirety. This includes application history documents that are inconsistent with or conflict with the content of this application, as well as documents (currently or subsequently attached to this application) that limit the broadest scope of the claims of this application. It should be noted that if the descriptions, definitions, and / or use of terms in the accompanying materials of this application are inconsistent or conflicting with the content of this application, the descriptions, definitions, and / or use of terms in this application shall prevail.

[0042] Finally, it should be understood that the embodiments described in this application are merely illustrative of the principles of the embodiments of this application. Other variations may also fall within the scope of this application. Therefore, by way of example and not limitation, alternative configurations of the embodiments of this application may be considered consistent with the teachings of this application. Accordingly, the embodiments of this application are not limited to the embodiments explicitly introduced and described in this application.

Claims

1. A method for preparing a three-dimensional object using additive manufacturing technology, characterized in that The three-dimensional object includes a cavity, the cavity includes an inner surface and an outer surface, the inner surface and the outer surface are the inner surface and the outer surface of the three-dimensional object, and the method includes: a) obtaining a flipped digital model of the three-dimensional object, wherein the flipped digital model is obtained by flipping the digital model of the three-dimensional object about the cavity and exchanging the inner and outer surfaces; b) adding a support structure to the flipped digital model to obtain a printed model, wherein the support structure is connected to an outer surface of the flipped digital model of the three-dimensional object; c) printing the printing model using additive manufacturing technology to obtain a printed part including a support structure; d) Remove the support structure on the printed part; e) Flipping the cavity of the printed part so that the inner and outer surfaces are exchanged to obtain the desired three-dimensional object.

2. The method according to claim 1, characterized in that The flipped digital model of the three-dimensional object has the same structure as the digital model of the three-dimensional object before flipping.

3. The method according to claim 1, characterized in that After the support structure is removed, all contact points between the support structure and the three-dimensional object are located on the inner surface of the three-dimensional object.

4. The method according to claim 1, wherein The method further includes polishing the outer surface of the printed part cavity after the support structure is removed.

5. The method according to claim 1, wherein The three-dimensional object is a casing.

6. The method according to claim 1, characterized in that The three-dimensional object is a shoe cover or a sock cover.

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