Support structure and printing method for 3D printing overhanging surfaces

Abstract

The present application relates to a kind of support structure and printing method for 3D printing overhanging face, belong to 3D printing technical field, solve the problem of the weight of the large number of parts and the large amount of internal volume of parts occupied by the large number of parts of existing support structure.The support structure includes a plurality of prismatic support blocks arranged below the overhanging face and a support frame arranged below the prismatic support blocks;The upper end surface of the prismatic support block is larger than the lower end surface, the upper end surface of the prismatic support block forms the entire overhanging face, the lower end surface of the prismatic support block coincides with the upper end surface of the support frame, and the lower end surface of the support frame is connected with the adjacent inclined surface;The adjacent inclined surface is located on one side below the overhanging face, and is arranged at an angle with the overhanging face.The support structure avoids the large amount of weight increase of parts and the large amount of internal volume of parts.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of 3D printing, and in particular to a support structure for 3D printing overhanging surfaces and a printing method. BACKGROUND

[0002] With the continuous development of 3D printing technology, more and more parts are trial-produced or mass-produced by 3D printing. In the part design process, there are inevitably some installation structures, alignment structures and the like which need to use planar or large curved surface structure forms. In the additive manufacturing printing process, the inclined surface with a forming angle greater than 45° to the vertical direction (i.e. an angle less than 45° to the horizontal plane) has the problem of poor printing quality, or even cannot be formed. In this case, the support structure is increased to ensure the printing formation of the part, and then the support structure is removed after formation to obtain the part. However, the internal support structure of the part is difficult to remove (such as a closed cavity structure), and a large amount of support not only increases the weight of the part but also occupies the internal volume of the part.

[0003] Therefore, it is necessary to design a support structure which can be self-formed, removed, and has a small occupied space volume, so as to solve the problem of difficult formation of overhanging surfaces. SUMMARY

[0004] In view of the above analysis, the embodiments of the present application aim to provide a support structure for 3D printing overhanging surfaces and a printing method, so as to solve the problem of the large amount of existing support structures which increase the weight of the part and occupy a large internal volume of the part.

[0005] In one aspect, the present application provides a support structure for 3D printing overhanging surfaces, the support structure comprising a plurality of prism support blocks arranged below the overhanging surface and a support frame arranged below the prism support blocks.

[0006] The upper end surface of the prism support block is larger than the lower end surface, the upper end surface of the prism support block coincides with the overhanging surface, the lower end surface of the prism support block coincides with the upper end surface of the support frame, and the lower end surface of the support frame is connected with the adjacent inclined surface.

[0007] The adjacent inclined surface is located on one side below the overhanging surface and is arranged at an angle with the overhanging surface.

[0008] Preferably, each prism support block is a quadrangular prism.

[0009] Preferably, the lower end surfaces of the plurality of prism support blocks are located on the same plane.

[0010] Preferably, the angle between the side surface of the prism support block and the horizontal plane is greater than or equal to 45°.

[0011] Preferably, the upper end face and the lower end face of the prism support block are square, the side length of the upper end face is 4-8mm, and the side length of the lower end face is 0.5-2mm.

[0012] Preferably, the support frame comprises a first-level support frame and a second-level support frame arranged in sequence from top to bottom.

[0013] The first-level support frame comprises four columns, the upper end faces of the four columns are connected with the lower end faces of four adjacent prism support blocks respectively, and the lower end faces of the four columns are connected with each other to form the lower end face of the first-level support frame.

[0014] The upper end face of the second-level support frame is connected with the lower end face of the first-level support frame, and the lower end face of the second-level support frame is connected with the adjacent inclined surface.

[0015] Preferably, the angle between each column of the first-level support frame and the horizontal plane is greater than or equal to 45°, and the angle between the second-level support frame and the horizontal plane is greater than or equal to 45°.

[0016] Preferably, the overhanging surface is a plane, a curved surface or a boss structure.

[0017] Preferably, the angle between the adjacent inclined surface and the horizontal plane is greater than or equal to 45°.

[0018] In another aspect, the present application also provides a 3D printing method of an overhanging surface, which adopts the above support structure, and the method comprises:

[0019] (a) printing an adjacent inclined surface;

[0020] (b) printing a second-level support frame from one side of the adjacent inclined surface;

[0021] (c) printing a first-level support frame from the upper end face of the second-level support frame;

[0022] (d) printing a prism support block from the upper end face of the first-level support frame;

[0023] (e) printing an overhanging surface on the upper end face of the prism support block.

[0024] Compared with the prior art, the present application can at least achieve one of the following beneficial effects:

[0025] 1. The prismatic support block converts the area of the overhanging surface from the area of the large end surface (upper end surface) of the prismatic support block to the area of the small end surface (lower end surface) of the prismatic support block, and the two ends of the support frame are connected with the small end surface of the prismatic support block and the adjacent inclined surface, respectively, to achieve the effect of support and further reduce the support surface. The weight of the support structure is only within 20% of the weight of the existing solid support structure, and the internal volume of the part is only within 20% of the internal volume of the existing solid support structure, avoiding the problem of greatly increasing the weight and internal volume of the part. The support structure does not need to be removed.

[0026] 2. The lower end surfaces of the plurality of prismatic support blocks of the present application are located on the same horizontal plane, and the overhanging surface of various special-shaped surfaces can be converted into a plane, so the support structure of the present application is suitable for any special-shaped overhanging surface.

[0027] 3. The 3D printing method of the present application can realize the printing self-forming of the overhanging surface, solve the problem of difficult forming in the printing process of the overhanging surface, and realize the printing self-forming of the overhanging surface in a way of adding less material weight.

[0028] In the present application, the above-mentioned technical solutions can be combined with each other to realize more preferred combination schemes. Other features and advantages of the present application will be described in the subsequent specification, and some advantages will become apparent from the specification or be understood by implementing the present application. The purpose and other advantages of the present application can be achieved and obtained through the contents specifically pointed out in the specification and the drawings. BRIEF DESCRIPTION OF DRAWINGS

[0029] The accompanying drawings are included to provide a further understanding of the embodiments, and are not considered limiting of the application. In the drawings, like reference numerals indicate like parts throughout the several views.

[0030] Figure 1 A 3D printing overhanging surface support structure provided by an embodiment of the present application is shown in the perspective view;

[0031] Figure 2 A 3D printing overhanging surface support structure provided by an embodiment of the present application is shown in the front view;

[0032] Figure 3 A 3D printing overhanging surface support structure provided by an embodiment of the present application is shown in the side view;

[0033] Figure 4 A prismatic support block structure of the present application is shown in the schematic view;

[0034] Figure 5 A 3D printing overhanging surface support structure provided by another embodiment of the present application is shown in the perspective view.

[0035] Reference signs:

[0036] 1-Suspended surface; 2-Frustum support block; 3-Primary support frame; 4-Secondary support frame; 5-Adjacent inclined surface; 6-Intermediate support frame. Detailed Implementation

[0037] Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, which form part of this application and are used together with the embodiments of the present invention to illustrate the principles of the present invention, but are not intended to limit the scope of the present invention.

[0038] On the one hand, the present invention provides a support structure for 3D printed overhanging surfaces, such as... Figures 1-3 As shown, the support structure includes multiple frustum support blocks 2 disposed below the suspended surface 1 and a support frame disposed below the frustum support blocks 2;

[0039] The upper end face of the frustum support block 2 is larger than the lower end face. The upper end face of the frustum support block 2 coincides with the suspended surface 1. The lower end face of the frustum support block 2 coincides with the upper end face of the support frame. The lower end face of the support frame is connected to the adjacent inclined surface 5.

[0040] The adjacent inclined surface 5 is located on one side below the suspended surface 1 and is set at an angle to the suspended surface 1.

[0041] Compared with the prior art, the support structure of the present invention converts the area of ​​the suspended surface from the area of ​​the large end face (upper end face) of the frustum support block 2 to the area of ​​the small end face (lower end face) of the frustum support block 2 through the frustum support block 2. At the same time, both ends of the support frame are connected to the small end face of the frustum support block 2 and the adjacent inclined surface 5, respectively, to achieve the effect of support and further reduce the support surface. The weight of this support structure is less than 20% of the weight of the existing solid support structure, and the internal volume occupied by the part is less than 20% of the existing solid support structure, avoiding the problems of greatly increasing the weight of the part and greatly occupying the internal volume of the part. This support structure does not need to be removed.

[0042] It should be noted that, unless otherwise specified, "upper" and "lower" in this invention refer to "upper" and "lower" in the main view of the part.

[0043] In this invention, the overhanging surface 1 is a surface that needs support or a part of a surface that needs support. The angle between the overhanging surface 1 and the horizontal plane is less than 45°, which does not meet the self-forming conditions of 3D printed parts without support or results in poor surface quality after forming. The structural shape of the overhanging surface 1 includes, but is not limited to, planes, curved surfaces, boss structures, etc. Its main characteristic is that it cannot self-form during the forming process. The wall thickness of the overhanging surface 1 can be any value greater than 0.5 mm. The upper and lower surfaces of the overhanging surface 1 may include local feature structures such as bosses, through holes, and reinforcing ribs.

[0044] In the present application, the role of the prism support block 2 is to convert the area of the overhanging surface 1 from the area of the upper end surface of the prism support block 2 to the area of the lower end surface, that is, from a large area to a small area, thereby reducing the area that needs to be supported.

[0045] It should be noted that the prism support block 2 is a solid structure.

[0046] In an embodiment, as shown in the drawings, each of the prism support blocks 2 is a quadrangular prism. Figures 1-4

[0047] It can be understood that the upper end surfaces of the plurality of prism support blocks 2 constitute the overhanging surface 1, that is, the overhanging surface 1 is divided into a plurality of squares, and each square extends downward to form a prism support block 2.

[0048] In an embodiment, the lower end surfaces of the plurality of prism support blocks 2 are located on the same plane. The prism support block 2 can convert various irregular overhanging surfaces 1 into a plane formed by the lower end surfaces of the prism support blocks 2, thereby improving the stability of the support.

[0049] Further, the lower end surface of the prism support block 2 is a horizontal surface.

[0050] In order to ensure the self-forming printing of the prism support block 2, the angle between the side surface of the prism support block 2 and the horizontal surface is greater than or equal to 45°.

[0051] In the present application, the area of the upper end surface of the prism support block 2 determines the area of the overhanging plane that each prism support block 2 can support, the area of the lower end surface of the prism support block 2 determines the area of the end surface of the support frame connected thereto, and further determines the structural strength of the support frame. Therefore, the size of the upper end surface and the lower end surface of the prism support block 2 can be adjusted according to the stress level of the support structure.

[0052] In an embodiment, the upper end surface and the lower end surface of the prism support block 2 are square, the side length of the upper end surface is 4-8 mm, and the side length of the lower end surface is 0.5-2 mm.

[0053] In an embodiment, the support frame comprises a primary support frame 3 and a secondary support frame 4 arranged in sequence from top to bottom; and the support structure comprises a plurality of primary support frames 3 and a plurality of secondary support frames 4.

[0054] The primary support frame 3 comprises four columns, the upper end surfaces of the four columns are respectively connected to the lower end surfaces of four adjacent prism support blocks 2, and the lower end surfaces of the four columns are connected to each other to form the lower end surface of the primary support frame 3; the “adjacent” refers to four prism support blocks 2 that can form a square.

[0055] ​The upper end surface of the secondary support frame 4 is connected with the lower end surface of the primary support frame 3, and the lower end surface of the secondary support frame 4 is connected with the adjacent inclined surface 5.

[0056] It can be understood that four columns extend downward from the lower end surfaces of the four adjacent prismatic support blocks 2, and the lower end surfaces of the four columns are connected with each other to form a primary support frame 3. The primary support frame 3 is used to convert the four lower end surfaces of the four prismatic support blocks 2 into one support surface on the upper end of the primary support frame 3, so as to further reduce the area of the required support surface and the volume of the support frame structure; and the primary support frame 3 is used to support the printing forming of the prismatic support block 2.

[0057] In an embodiment, the lower end surface of the primary support frame 3 is a horizontal surface.

[0058] In an embodiment, the upper end surface of the primary support frame 3 is consistent with and completely coincides with the lower end surface of the prismatic support block 2.

[0059] In the present application, the lower end surface of the primary support frame 3 is used to be connected with the upper end surface of the secondary support frame 4. The cross-sectional shape and area of the lower end surface of the primary support frame 3 can be adjusted according to the strength requirement of the support structure. The cross-sectional shape and area of the lower end surface of the primary support frame 3 can be different from those of the upper end surface of the primary support frame 3.

[0060] Exemplarily, the cross-sectional shape of the lower end surface of the primary support frame 3 is circular, elliptical, rectangular, etc., and the cross-sectional area is larger or smaller than that of the upper end surface.

[0061] It can be understood that the secondary support frame 4 is formed by extending from the lower end surface of the primary support frame 3 to the adjacent inclined surface 5. The secondary support frame 4 is used to support the printing forming of the primary support frame 3.

[0062] In an embodiment, the upper end surface of the secondary support frame 4 is consistent with and completely coincides with the lower end surface of the primary support frame 3.

[0063] In the present application, the cross-sectional shape and area of the lower end surface of the secondary support frame 4 can be adjusted according to the strength requirement of the support structure.

[0064] Exemplarily, the cross-sectional shape of the lower end surface of the secondary support frame 4 is circular, elliptical, rectangular, etc., and the cross-sectional area is larger or smaller than that of the upper end surface.

[0065] In order to ensure the self-forming printing of the primary support frame 3 and the secondary support frame 4, the angle between each column of the primary support frame 3 and the horizontal surface is greater than or equal to 45°, and the angle between the secondary support frame 4 and the horizontal surface is greater than or equal to 45°.

[0066] It should be noted that when the area of the required support is large, an intermediate support frame 6 similar to the first support frame 3 can be arranged between the first support frame 3 and the second support frame 4 to further reduce the support area.

[0067] As shown in the examples, Figure 2 and 3 four intermediate supports extend downward from the lower end faces of four adjacent first support frames 3, the upper end faces of the four intermediate supports are respectively connected with the lower end faces of the four adjacent first support frames 3, and the lower end faces of the four intermediate supports are respectively connected with each other, thereby reducing the area of the four lower end faces of the four first support frames 3 to the lower end face of an intermediate support frame 6, and the lower end face of the intermediate support frame 6 is connected with the upper end face of the second support frame 4. The angle between each support of the intermediate support frame 6 and the horizontal plane is greater than or equal to 45°.

[0068] In the present application, the intermediate support frame 6 can be multiple, and the arrangement is as described above, for reducing the overall support area step by step.

[0069] In an embodiment, the second support frame 4 is rod-shaped, the upper end face of the rod is connected with the lower end face of the first support frame 3 or the intermediate support frame 6, and the lower end face of the second support frame 4 is connected with the adjacent inclined surface 5.

[0070] In an embodiment, the second support frame 4 is a vertically placed flat plate, the top side of the flat plate is connected with the lower end face of one or more first support frames 3 or intermediate support frames 6, and one side of the flat plate is connected with the adjacent inclined surface 5.

[0071] It can be understood that when the required support strength of the part is high, the structure of the second support frame 4 can be changed from one end face connected with the adjacent inclined surface 5 to the entire side of the second support frame 4 connected with the adjacent inclined surface 5, i.e. the second support frame 4 is a right triangle plate perpendicular to the overhanging surface 1 and the adjacent inclined surface 5, two right angles are respectively parallel to the overhanging surface 1 and the adjacent inclined surface 5, and one of the right angles is used to connect with the first support frame 3, and the other right angle is connected with the adjacent inclined surface 5, as shown in Figure 5 which can increase the connection strength of the second support frame 4 and the adjacent inclined surface 5, and prevent deformation and cracking of the connection position due to excessive stress.

[0072] In the present application, the adjacent inclined surface 5 can be part of the part body, as shown in Figure 1 which is located below the overhanging surface 1 and one side is connected with one side of the overhanging surface 1.

[0073] In an embodiment, the adjacent inclined surface 5 has an angle greater than or equal to 45° with the horizontal plane. The adjacent inclined surface 5 can be directly printed and shaped, and can be used to connect with the structure of the secondary support frame 4, and can support the secondary support frame 4 and the structure above the secondary support frame 4. Similarly, the structure of the adjacent inclined surface 5 can be connected with the structure of the primary support frame 3, and can support the primary support frame 3 and the structure above the primary support frame 3. The structure of the adjacent inclined surface 5 can be connected with the structure of the prism support block 2, and can support the prism support block 2 and the overhanging surface 1 above the prism support block 2.

[0074] The form of the adjacent inclined surface 5 is not limited to a plane, and can be a curved surface or a special-shaped surface in various forms, as long as the self-shaping condition of the overhanging surface 1 is met.

[0075] In another aspect, the present application also provides a 3D printing method of an overhanging surface, which uses the above support structure, and the method comprises the following steps:

[0076] (a) printing the adjacent inclined surface 5;

[0077] (b) printing the secondary support frame 4 from one side of the adjacent inclined surface 5;

[0078] (c) printing the primary support frame 3 from the upper end surface of the secondary support frame 4;

[0079] (d) printing the prism support block 2 from the upper end surface of the primary support frame 3;

[0080] (e) printing the overhanging surface 1 on the upper end surface of the prism support block 2.

[0081] Specifically, in the 3D printing process, the adjacent inclined surface 5 is first printed and shaped, then the secondary support frame 4 is gradually printed and shaped from one side of the adjacent inclined surface 5, the primary support frame 3 is gradually printed and shaped by the upper end surface support of the secondary support frame 4, the upper end surface of each column of the primary support frame 4 supports the prism support block 2 to be printed and shaped, and finally, the overhanging surface 1 is printed and shaped on the upper end surface of the prism support block 2, and the 3D printing of the overhanging surface 1 is completed.

[0082] The 3D printing method of the present application can realize the self-shaping of the overhanging surface, and solves the problem of difficult shaping in the printing process of the overhanging surface. The self-shaping of the overhanging surface is realized in a way of adding less material weight, and the support structure is removed.

[0083] In the following, the support structure and the printing method for 3D printing of the overhanging surface of the present application are further described through specific embodiments.

[0084] Embodiment 1-1

[0085] A support structure for 3D printing of an overhanging surface is provided, which comprises: Figure 1As shown in the figure: 5 the support structure includes a plurality of prism support blocks 2 arranged below the overhanging surface 1 and a support frame arranged below the prism support blocks 2; the upper end surface of the prism support block 2 is larger than the lower end surface, the upper end surface of the prism support block 2 coincides with the overhanging surface 1, the lower end surface of the prism support block 2 coincides with the upper end surface of the support frame, and the lower end surface of the support frame is connected with the adjacent inclined surface 5; the adjacent inclined surface 5 is located on one side below the overhanging surface 1 and is arranged at an angle with the overhanging surface 1.

[0086] The prism support block 2 is a solid structure. Each of the prism support blocks 2 is a quadrangular prism. The upper end surfaces of the plurality of prism support blocks 2 constitute the overhanging surface 1, i.e., the overhanging surface 1 is divided into a plurality of squares, which are the upper end surfaces of the prism support blocks 2, and each square extends downward to form a prism support block 2. The lower end surfaces of the plurality of prism support blocks 2 are located on the same plane. The lower end surface of the prism support block 2 is a horizontal plane. The angle between the side surface of the prism support block 2 and the horizontal plane is equal to 45°. The upper end surface and the lower end surface of the prism support block 2 are square. The side length of the upper end surface is 5 mm, and the side length of the lower end surface is 1 mm.

[0087] The support frame includes a first-level support frame 3 and a second-level support frame 4 arranged in sequence from top to bottom. The support structure includes a plurality of first-level support frames 3 and a plurality of second-level support frames 4. The first-level support frame 3 includes four columns, the upper end surfaces of the four columns are respectively connected with the lower end surfaces of four adjacent prism support blocks 2, and the lower end surfaces of the four columns are connected with each other to form the lower end surface of the first-level support frame 3. The upper end surface of the second-level support frame 4 is connected with the lower end surface of the first-level support frame 3, and the lower end surface of the second-level support frame 4 is connected with the adjacent inclined surface 5. The lower end surface of the first-level support frame 3 is a horizontal plane. The upper end surface of the first-level support frame 3 is consistent with and completely coincides with the lower end surface of the prism support block 2. The upper end surface of the second-level support frame 4 is consistent with and completely coincides with the lower end surface of the first-level support frame 3. The angle between each column of the first-level support frame 3 and the horizontal plane is greater than or equal to 45°, and the angle between the second-level support frame 4 and the horizontal plane is greater than or equal to 45°.

[0088] Embodiment 1-2

[0089] A support structure for 3D printing an overhanging surface is provided, as shown in Figure 2 As shown in the figure:

[0090] The support structure comprises a plurality of prismatic support blocks 2 arranged below the overhanging surface 1 and a support frame arranged below the prismatic support blocks 2; the upper end surface of the prismatic support block 2 is larger than the lower end surface, the upper end surface of the prismatic support block 2 coincides with the overhanging surface 1, the lower end surface of the prismatic support block 2 coincides with the upper end surface of the support frame, and the lower end surface of the support frame is connected with the adjacent inclined surface 5; the adjacent inclined surface 5 is located on one side below the overhanging surface 1 and is arranged at an angle with the overhanging surface 1.

[0091] The prismatic support block 2 is a solid structure. Each prismatic support block 2 is a quadrangular prism. The upper end surfaces of the plurality of prismatic support blocks 2 constitute the overhanging surface 1, i.e., the overhanging surface 1 is divided into a plurality of squares, which are the upper end surfaces of the prismatic support blocks 2, and each square extends downward to form a prismatic support block 2. The lower end surfaces of the plurality of prismatic support blocks 2 are located on the same plane. The lower end surface of the prismatic support block 2 is a horizontal plane. The angle between the side surface of the prismatic support block 2 and the horizontal plane is equal to 45°. The upper end surface and the lower end surface of the prismatic support block 2 are squares. The side length of the upper end surface is 5 mm, and the side length of the lower end surface is 1 mm.

[0092] The support frame comprises a primary support frame 3 and a secondary support frame 4 arranged in sequence from top to bottom. The support structure comprises a plurality of primary support frames 3 and a plurality of secondary support frames 4. The primary support frame 3 comprises four columns, the upper end surfaces of the four columns are respectively connected with the lower end surfaces of four adjacent prismatic support blocks 2, and the lower end surfaces of the four columns are connected with each other to form the lower end surface of the primary support frame 3. The upper end surface of the secondary support frame 4 is connected with the lower end surface of the primary support frame 3, and the lower end surface of the secondary support frame 4 is connected with the adjacent inclined surface 5. The lower end surface of the primary support frame 3 is a horizontal plane. The upper end surface of the primary support frame 3 is consistent with and completely coincides with the lower end surface of the prismatic support block 2. The upper end surface of the secondary support frame 4 is consistent with and completely coincides with the lower end surface of the primary support frame 3. The angle between each column of the primary support frame 3 and the horizontal plane is greater than or equal to 45°, and the angle between the secondary support frame 4 and the horizontal plane is greater than or equal to 45°.

[0093] An intermediate support frame 6 similar in structure to the primary support frame 3 is arranged between the primary support frame 3 and the secondary support frame 4.

[0094] Embodiments 1-3

[0095] A support structure for 3D printing an overhanging surface is provided, as shown in Figure 5

[0096] ​The support structure comprises a plurality of prismatic support blocks 2 arranged below the overhanging surface 1 and a support frame arranged below the prismatic support blocks 2; the upper end surface of the prismatic support block 2 is larger than the lower end surface, the upper end surface of the prismatic support block 2 coincides with the overhanging surface 1, the lower end surface of the prismatic support block 2 coincides with the upper end surface of the support frame, and the lower end surface of the support frame is connected with the adjacent inclined surface 5; the adjacent inclined surface 5 is located on one side below the overhanging surface 1 and is arranged at an angle with the overhanging surface 1.

[0097] The prismatic support block 2 is a solid structure. Each prismatic support block 2 is a quadrangular prism. The upper end surfaces of the plurality of prismatic support blocks 2 constitute the overhanging surface 1, i.e., the overhanging surface 1 is divided into a plurality of squares, which are the upper end surfaces of the prismatic support blocks 2, and each square extends downward to form a prismatic support block 2. The lower end surfaces of the plurality of prismatic support blocks 2 are located on the same plane. The lower end surface of the prismatic support block 2 is a horizontal plane. The angle between the side surface of the prismatic support block 2 and the horizontal plane is equal to 45°. The upper end surface and the lower end surface of the prismatic support block 2 are squares. The side length of the upper end surface is 5 mm, and the side length of the lower end surface is 1 mm.

[0098] The support frame comprises a first-level support frame 3 and a second-level support frame 4 arranged in sequence from top to bottom. The support structure comprises a plurality of first-level support frames 3 and a plurality of second-level support frames 4. The first-level support frame 3 comprises four columns, the upper end surfaces of the four columns are respectively connected with the lower end surfaces of four adjacent prismatic support blocks 2, and the lower end surfaces of the four columns are connected with each other to form the lower end surface of the first-level support frame 3. The upper end surface of the second-level support frame 4 is connected with the lower end surface of the first-level support frame 3, and the lower end surface of the second-level support frame 4 is connected with the adjacent inclined surface 5. The lower end surface of the first-level support frame 3 is a horizontal plane. The upper end surface of the first-level support frame 3 is consistent with and completely coincides with the lower end surface of the prismatic support block 2. The upper end surface of the second-level support frame 4 is consistent with and completely coincides with the lower end surface of the first-level support frame 3. The angle between each column of the first-level support frame 3 and the horizontal plane is greater than or equal to 45°, and the angle between the second-level support frame 4 and the horizontal plane is greater than or equal to 45°.

[0099] An intermediate-level support frame 6 similar in structure to the first-level support frame 3 is arranged between the first-level support frame 3 and the second-level support frame 4.

[0100] The entire side surface of the second-level support frame 4 is connected with the adjacent inclined surface 5, i.e., the second-level support frame 4 is a right-angled triangular plate perpendicular to the overhanging surface 1 and the adjacent inclined surface 5 at the same time, two right-angled sides are respectively parallel to the overhanging surface 1 and the adjacent inclined surface 5 perpendicular to each other, one of the right-angled sides is used for connecting with the first-level support frame 3, and the other right-angled side is connected with the adjacent inclined surface 5.

[0101] Example 2-1

[0102] The embodiment provides a 3D printing method of overhanging surface, comprising the following steps:

[0103] (a) printing an adjacent inclined surface 5, the adjacent inclined surface 5 being 90 degrees with a horizontal plane.

[0104] (b) printing a secondary support frame 4 from one side of the adjacent inclined surface 5, the secondary support frame 4 being 45 degrees with the horizontal plane.

[0105] (c) printing a primary support frame 3 from an upper end surface of the secondary support frame 4; the upper end surface of the secondary support frame 4 being consistent with and completely coinciding with a lower end surface of the primary support frame 3; the primary support frame 3 being 45 degrees with the horizontal plane.

[0106] (d) printing a prism support block 2 from an upper end surface of each column of the primary support frame 3; the upper end surface of each column of the primary support frame 3 being consistent with and completely coinciding with a lower end surface of the prism support block 2; the upper end surface and the lower end surface of the prism support block 2 being square, the side length of the upper end surface being 5mm, and the side length of the lower end surface being 1mm; the side surface of the prism support block 2 being 45 degrees with the horizontal plane.

[0107] (e) printing an overhanging surface 1 on the upper end surface of the prism support block 2, the overhanging surface 1 being 0 degrees with the horizontal plane.

[0108] The weight of the support structure is only 18% of the solid support, and the occupied internal volume of the part is 18% of the solid support. The solid support refers to a complete solid triangular support formed between the overhanging surface and the adjacent inclined surface and formed by 3D printing.

[0109] Embodiment 2-2

[0110] The embodiment provides a 3D printing method of overhanging surface, comprising the following steps:

[0111] (a) printing an adjacent inclined surface 5, the adjacent inclined surface 5 being 85 degrees with a horizontal plane.

[0112] (b) printing a secondary support frame 4 from one side of the adjacent inclined surface 5, the secondary support frame 4 being 50 degrees with the horizontal plane.

[0113] (c) printing an intermediate support frame 6 from an upper end surface of the secondary support frame 4; the upper end surface of the secondary support frame 4 being consistent with and completely coinciding with a lower end surface of the intermediate support frame 6; each support column of the intermediate support frame 6 being 50 degrees with the horizontal plane.

[0114] (d) printing a first level support frame 3 from the upper end surface of each strut of the intermediate level support frame 6; the upper end surface of each strut of the intermediate level support frame 6 is identical in shape and fully coincides with the lower end surface of the first level support frame 3; the angle between each column of the first level support frame 3 and the horizontal plane is 50°.

[0115] (e) printing a prismatic support block 2 from the upper end surface of each column of the first level support frame 3; the upper end surface of each column of the first level support frame 3 is identical in shape and fully coincides with the lower end surface of the prismatic support block 2; the upper and lower end surfaces of the prismatic support block 2 are square, the side length of the upper end surface is 5mm, and the side length of the lower end surface is 1mm; the angle between the side surface of the prismatic support block 2 and the horizontal plane is 50°.

[0116] (f) printing an overhanging face 1 on the upper end surface of the prismatic support block 2, the wall thickness of the overhanging face 1 is 0.6mm, and the angle between the overhanging face 1 and the horizontal plane is 5°.

[0117] The weight of the support structure is only 16.3% of the solid support, and the occupied internal volume of the part is 16.3% of the solid support. The solid support refers to a complete solid triangular support formed between the overhanging face, the adjacent inclined surface, which can be formed by 3D printing.

[0118] The above description is only the preferred embodiment of the present application, but the protection scope of the present application is not limited to this. Any person skilled in the art can easily think of changes or replacements within the technical range disclosed by the present application, which should be covered within the protection scope of the present application.

Claims

1. A support structure for 3D printing overhanging surfaces, characterized in that, The support structure comprises a plurality of prismatic support blocks (2) arranged below the overhanging surface (1) and a support frame arranged below the prismatic support blocks (2); The upper end surface of the prismatic support block (2) is larger than the lower end surface, the upper end surface of the prismatic support block (2) coincides with the overhanging surface (1), the lower end surface of the prismatic support block (2) coincides with the upper end surface of the support frame, and the lower end surface of the support frame is connected with the adjacent inclined surface (5); The prismatic support block (2) is used to convert the area of the overhanging surface (1) from the area of the upper end surface of the prismatic support block (2) to the area of the lower end surface, that is, from a large area to a small area, thereby reducing the area that needs to be supported; Each prismatic support block (2) is a quadrangular prism, the lower end surfaces of the plurality of prismatic support blocks (2) are located on the same plane, the angle between the side surface of the prismatic support block (2) and the horizontal plane is greater than or equal to 45°, the upper end surface and the lower end surface of the prismatic support block (2) are square, the side length of the upper end surface is 4-8 mm, and the side length of the lower end surface is 0.5-2 mm; The support structure does not need to be removed; The support frame comprises a first-level support frame (3) and a second-level support frame (4) arranged in sequence from top to bottom; The first-level support frame (3) comprises four columns, the upper end surfaces of the four columns are respectively connected with the lower end surfaces of four adjacent prismatic support blocks (2), and the lower end surfaces of the four columns are connected with each other to form the lower end surface of the first-level support frame (3); The upper end surface of the second-level support frame (4) is connected with the lower end surface of the first-level support frame (3), and the lower end surface of the second-level support frame (4) is connected with the adjacent inclined surface (5); The angle between each column of the first-level support frame (3) and the horizontal plane is greater than or equal to 45°, and the angle between the second-level support frame (4) and the horizontal plane is greater than or equal to 45°; The adjacent inclined surface (5) is located on one side below the overhanging surface (1) and is arranged at an angle with the overhanging surface (1).

2. The support structure of claim 1, wherein, The overhanging surface (1) is a plane or a curved surface.

3. The support structure of claim 1, wherein, The overhanging surface (1) is a convex structure.

4. The support structure of claim 1, wherein, The angle between the adjacent inclined surface (5) and the horizontal plane is greater than or equal to 45°.

5. A method of 3D printing of overhanging surfaces, characterized in that, The method comprises the following steps: (a) printing the adjacent inclined surface (5); (b) printing the second-level support frame (4) from one side of the adjacent inclined surface (5); (c) printing the first-level support frame (3) from the upper end surface of the second-level support frame (4); (d) printing the prismatic support block (2) from the upper end surface of the first-level support frame (3); (e) printing the overhanging surface (1) on the upper end surface of the prismatic support block (2).

Images