Fused deposition modeling method, apparatus, storage medium, and fused deposition modeling component

Abstract

The application relates to a fused deposition modeling method, a fused deposition modeling device, a storage medium and a fused deposition modeling component. The fused deposition modeling method comprises the following steps: obtaining a two-dimensional cross section profile of each layer slice according to a three-dimensional model of a target component; performing fused deposition in the two-dimensional cross section profile of each layer to form a printing cross section of each layer, the printing cross section being a primary crystallization region; performing heat pressing treatment on the printing cross section of a first specified layer to form a heat pressing region; and performing heat crystallization treatment on a specified region of the heat pressing region of a second specified layer to form a secondary crystallization region.

Description

Technical Field

[0001] This invention relates to the field of medical device technology, and in particular to a fused deposition modeling method, equipment, storage medium, and fused deposition modeling component. Background Technology

[0002] Fused Deposition Modelling (FDM) involves slicing the material using layering software and calculating the path of each layer. Then, the computer controls the movement of the printhead and platform. The printhead heats and melts the filamentary thermoplastic material, which is then extruded from the printhead and eventually solidified. The material is deposited on the previously solidified material, and the process is repeated layer by layer on the molding substrate to form the component.

[0003] Traditional fused deposition modeling (FDM) materials include ABS (acrylonitrile-butadiene-styrene copolymer) and PLA (polylactic acid). With the increasing popularity of high-performance plastic PEEK (polyether ether ketone), its high temperature resistance, corrosion resistance, and good biocompatibility make it one of the ideal materials for prosthetic implants, finding wide application not only in medical devices but also in aerospace and other fields.

[0004] Taking PEEK material as an example of medical device prostheses, the traditional technical solution is to form a highly crystalline layer on the overall surface of the prosthesis by fused deposition modeling of PEEK prostheses and then by global heat treatment or surface heat treatment. However, the strength of the resulting products still needs to be improved. Summary of the Invention

[0005] Therefore, it is necessary to provide a fused deposition modeling method that can improve product strength.

[0006] In addition, a fused deposition additive manufacturing apparatus, a computer device, a computer-readable storage medium, and a fused deposition molded component are also provided.

[0007] One aspect of the present invention provides a fused deposition modeling method, comprising the following steps:

[0008] Based on the three-dimensional model of the target component, obtain the two-dimensional cross-sectional profile of each slice.

[0009] Melt deposition is performed within the two-dimensional cross-sectional contour of each layer to form the printed cross-section of each layer, wherein the printed cross-section is a primary crystallization region;

[0010] Hot pressing is performed on the printed cross-section of the first designated layer to form a hot-pressed area; and

[0011] A thermal crystallization process is performed in a designated area of ​​the hot-pressing region of the second designated layer to form a secondary crystallization region.

[0012] The aforementioned fused deposition modeling method forms printing sections (i.e., primary crystallization regions) of each layer through fused deposition, and performs hot pressing treatment on the printing section of the first designated layer. This can reduce the gaps between the filaments in the printing section formed by the melting and extruding solidified filaments of the printing nozzle and / or between the printing sections of adjacent layers, which is beneficial to improving the density of the fused deposition modeled component. Then, a designated area of ​​the hot pressing region of the second designated layer is subjected to thermal crystallization treatment. The thermal crystallization treatment step is highly flexible and controllable, and can form secondary crystallization regions with high and uniform crystallinity at fixed points inside the molded component. It works synergistically from multiple aspects of density and crystallinity, which is beneficial to forming fused deposition modeled components with higher strength.

[0013] Furthermore, compared to the technical solution of obtaining a molded component through fused deposition modeling and then forming a highly crystalline layer on the overall surface of the molded component through global heat treatment or surface heat treatment, the above-mentioned fused deposition modeling method is highly operable. The hot pressing crystallization step can adjust the structure and setting position of the secondary crystallization region according to the strength requirements of the fused deposition modeled component. The secondary crystallization region can be the outer periphery or the interior of the printed section, and can form any shape and distribution, with extremely high degree of freedom. Moreover, the hot pressing crystallization step is performed on the printed section, and the hot crystallization treatment step follows the hot pressing treatment step, which can improve the density of the material. Compared with the heat treatment method that acts on the entire component, it can make the density and crystallization degree of the printed section material higher, thereby achieving a higher and more uniform crystallinity and higher material strength.

[0014] In any embodiment of this application, at least one of the following conditions is satisfied:

[0015] (1a) The hot pressing process is performed on the entire printed section of the first specified layer;

[0016] (1b) The first designated layer is all or part of the printed cross section of each layer;

[0017] (1c) The second designated layer is all or part of the first designated layer;

[0018] (1d) The designated area of ​​the hot-pressing area is all or part of the hot-pressing area.

[0019] In any embodiment of this application, in at least a portion of the second designated layer, the designated region is arranged around the edge of the hot-pressed region and forms an annular region.

[0020] In any embodiment of this application, the width of the annular region is 0.5 mm to 4 mm; and / or,

[0021] In each of the multiple second designated layers, the annular region accounts for 20% to 80% of the area of ​​the hot-pressed region independently.

[0022] In any embodiment of this application, there are multiple designated areas, and the multiple designated areas are distributed at intervals on the hot-pressing area.

[0023] In any embodiment of this application, the shape of the designated region is at least one of hexagonal, pentagonal, quadrilateral, triangular, and circular; and / or,

[0024] In each of the multiple second designated layers, the designated area accounts for 50% to 90% of the area of ​​the hot-pressed area, and can be optionally 60% to 90%.

[0025] In any embodiment of this application, the shape of the designated region is hexagonal;

[0026] The side length of the hexagon is 1mm to 20mm, and can be selected as 2mm to 10mm; and / or,

[0027] The spacing between two adjacent designated areas is 1mm to 10mm, and can be selected as 2mm to 4mm.

[0028] In any embodiment of this application, the shape of the designated area is rectangular;

[0029] The side length of the rectangle is 0.1mm to 100mm, and can be selected as 1mm to 20mm; and / or,

[0030] The spacing between two adjacent designated areas is 1mm to 5mm.

[0031] In any embodiment of this application, an angle is formed between the printing path used to form the printed cross section and the hot pressing path used to form the hot pressing area; optionally, the angle is 45° to 90°.

[0032] In any embodiment of this application, after the molded component is obtained by melt deposition, the following steps are further included:

[0033] At least a portion of the surface of the molded component is subjected to surface roughening treatment.

[0034] In any embodiment of this application, the surface roughening treatment is performed using a laser engraving method, with the laser being a CO2 laser and the laser density being 2 J / mm². 3 ~20J / mm 3 The distance between the laser and the surface of the molded component is 0 to 40 mm.

[0035] In any embodiment of this application, at least one of the following conditions is satisfied:

[0036] (2a) The raw material for the fused deposition includes polyetheretherketone;

[0037] (2b) The temperature of the molten deposition is 380℃~420℃;

[0038] (2c) The diameter of the filament extruded by the melt deposition process is 0.2 mm to 0.4 mm;

[0039] (2d) The temperature of the hot pressing treatment is 135℃~155℃;

[0040] (2e) The temperature of the thermal crystallization treatment is 260℃~320℃.

[0041] Another aspect of the present invention provides a fused deposition modeling (FDM) additive manufacturing apparatus, comprising:

[0042] A melt-forming mechanism is used to melt and deposit raw materials to form printed cross-sections of various layers; and

[0043] A hot-pressing crystallization mechanism is used to hot-press a printed section of a first specified layer to form a hot-pressed region, and to hot-crystallize a specified area of ​​the hot-pressed region of a second specified layer to form a secondary crystallization region.

[0044] In any embodiment of this application, the hot-press crystallization mechanism is a heat treatment nozzle.

[0045] In any embodiment of this application, the fused deposition additive manufacturing apparatus further includes a laser for surface roughening treatment of at least a portion of the surface of the shaped component obtained by the fused deposition modeling mechanism and the hot pressing crystallization mechanism.

[0046] In another aspect, a computer device is provided, including a memory and a processor, the memory storing a computer program, the processor executing the computer program to implement the steps of any of the methods described above.

[0047] In another aspect, the present invention provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the steps of the method described in any of the preceding claims.

[0048] In another aspect, the present invention provides a fused deposition modeled component, the component being made of polyetheretherketone (PEEK), at least one cross-section of the component including a secondary crystallization region, the crystallinity of the secondary crystallization region being 30%–38%, and the density of the component being ≥1.30 g / cm³. 3 ;

[0049] Alternatively, the molded component may be manufactured using any of the methods described above.

[0050] In any embodiment of this application, at least one cross section of the molded component includes a hot-pressed region and the secondary crystallization region, the secondary crystallization region being disposed around the hot-pressed region and forming an annular region, and the crystallinity of the hot-pressed region being lower than that of the secondary crystallization region.

[0051] In any embodiment of this application, the fused deposition modeling component includes an inner layer and an outer layer enclosing the inner layer, wherein the outer layer is the secondary crystallization region and the inner layer is a hot-pressed region; and / or,

[0052] The thickness of the secondary crystallization region is 0.5 mm to 4 mm; and / or,

[0053] The secondary crystallization region accounts for 20% to 80% of the volume of the fused deposition modeled component, and can be selected as 30% to 70%.

[0054] In another aspect of the present invention, a fused deposition modeling component is provided, wherein at least one cross section of the component includes a primary crystallization region and a plurality of secondary crystallization regions, the plurality of secondary crystallization regions being distributed at intervals on the cross section and connected through the primary crystallization region, wherein the crystallinity of the primary crystallization region is lower than that of the secondary crystallization region.

[0055] In any embodiment of this application, the shape of the secondary crystallization region is at least one of hexagonal, pentagonal, quadrilateral, triangular and circular.

[0056] In any embodiment of this application, the secondary crystallization region is hexagonal in shape;

[0057] The side length of the hexagon is 1mm to 20mm, and can be selected as 2mm to 10mm; and / or,

[0058] The spacing between two adjacent secondary crystallization regions is 1 mm to 10 mm, optionally 2 mm to 4 mm; and / or,

[0059] The secondary crystallization region accounts for 50% to 90% of the area of ​​the cross section, and can be selected as 60% to 90%.

[0060] In any embodiment of this application, the secondary crystallization region is rectangular in shape;

[0061] The side length of the rectangle is 0.1mm to 100mm, and can be selected as 1mm to 20mm; and / or,

[0062] The spacing between two adjacent secondary crystallization regions is 1 mm to 5 mm; and / or,

[0063] The secondary crystallization region accounts for 50% to 90% of the area of ​​the cross section, and can be selected as 60% to 90%.

[0064] In any embodiment of this application, the molded component includes a primary crystalline continuous phase and a secondary crystalline reinforcing structure distributed in the primary crystalline continuous phase.

[0065] In any embodiment of this application, the material of the molded component includes polyetheretherketone (PEEK), the crystallinity of the secondary crystallization region is 30%–38%, and the density of the molded component is ≥1.30 g / cm³. 3 ;

[0066] Alternatively, the molded component may be manufactured using any of the methods described above, and the primary crystallization region may be further subjected to hot pressing to form a hot-pressed region. Attached Figure Description

[0067] Figure 1 A schematic diagram of the printing path used to form the printed cross section and the hot pressing path used to form the hot pressing area;

[0068] Figure 2 This is a schematic diagram of the heat treatment nozzle and its two-dimensional cross-sectional profile.

[0069] Figure 3 A schematic diagram mimicking the structure of the human skeleton;

[0070] Figure 4 A schematic diagram of a skull prosthesis that mimics the structure of the human skeleton;

[0071] Figure 5 A schematic diagram of a tortoise shell biomimetic structure;

[0072] Figure 6 A schematic diagram of a skull prosthesis with a tortoise shell-like biomimetic structure;

[0073] Figure 7 A schematic diagram of a brick-and-mortar biomimetic structure;

[0074] Figure 8 A schematic diagram of a skull prosthesis with a brick-and-mortar biomimetic structure;

[0075] Figure 9 The images are scanning electron microscope (SEM) images of a printed cross-section of Example 1 before hot pressing and after heat treatment but before thermal crystallization.

[0076] Figure 10 The images are scanning electron microscope (SEM) images of the skull prosthesis of Example 1 before and after laser engraving.

[0077] Explanation of reference numerals in the attached figures:

[0078] 101. The printing path used to form the printed cross-section;

[0079] 102. The hot pressing path used to form the hot pressing zone;

[0080] 201. Cortical bone; 202. Cancellous bone; 110. Inner layer; 120. Outer layer. Detailed Implementation

[0081] To facilitate understanding of the present invention, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of the invention are shown in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. It should be understood that these embodiments are provided to provide a thorough and complete understanding of the disclosure of the present invention.

[0082] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items. In the description of the invention, "a plurality of" means two or more, unless otherwise expressly specified.

[0083] One embodiment of the present invention provides a fused deposition modeling method, comprising the following steps S10 to S40.

[0084] S10. Based on the three-dimensional model of the target component, obtain the two-dimensional cross-sectional contours of each slice.

[0085] Understandably, the three-dimensional model of the target component can be obtained through software.

[0086] It is understood that the two-dimensional cross-sectional contours of each slice of a 3D model can be obtained through programming slicing software. For example, the 3D model can be, but is not limited to, a 3D model of a skull prosthesis. It is understood that the two-dimensional cross-sectional contours are closed shapes, including but not limited to polygons.

[0087] S20. Perform molten deposition within the two-dimensional cross-sectional contour of each layer to form the printed cross-section of each layer.

[0088] The principle of fused deposition modeling (FDM) is to use low-melting-point filaments as raw materials. These filaments are heated and melted into a molten state, then extruded through a printhead. The printhead moves precisely along the two-dimensional cross-sectional contours of each layer of the 3D model, extruding semi-fluid thermoplastic material that is deposited and solidified into a precise thin layer of the actual part – the aforementioned printed cross-section (or printed layer). This layer covers the already constructed part and rapidly solidifies; this is the primary crystallization process. The printed cross-section is also called the primary crystallization region. After each layer is completed, the worktable descends one level, and the printhead scans and spins the filament for the next layer's two-dimensional cross-sectional contour. This process is repeated layer by layer until the last layer is reached. By accumulating these printed cross-sections from bottom to top, a solid molded component is formed.

[0089] S30. Perform hot pressing on the printed section of the first designated layer to form a hot pressing area.

[0090] It is understandable that the hot pressing process in S30 is performed after printing the specified layer in step S20 and before printing the next layer.

[0091] Furthermore, the first designated layer can be all or part of the printed cross-section of each layer. That is, the above-mentioned hot-pressing treatment can be performed after the printed cross-section of each layer is formed, or the hot-pressing treatment can be performed on the printed cross-section of some layers. After printing one or more layers by fused deposition modeling, the printed cross-section formed by the molten and extruded solidified filament from the print head is subjected to hot-pressing treatment to reduce the gaps between the filaments in the printed cross-section and / or between the printed cross-sections of adjacent layers, which helps to improve the density of the fused deposition modeled component.

[0092] For example, the hot-pressing process described above can be performed after every N layers of fused deposition, where N can be an integer ≥1, such as 1, 2, 3, etc. For instance, N is an integer between 1 and 5. When N is 1, the hot-pressing process described above is performed after each layer of fused deposition. When N is 2, the hot-pressing process described above is performed after even-numbered layers of fused deposition, and not after odd-numbered layers of fused deposition.

[0093] In some embodiments, the hot pressing process is performed on the entire printed section of the first designated layer to improve the uniformity of the molded component.

[0094] S40. Perform thermal crystallization treatment in a designated area of ​​the hot-pressing region of the second designated layer to form a secondary crystallization region.

[0095] It can be understood that the second specified layer is specified within the first specified layer. In other words, the second specified layer is all or part of the first specified layer.

[0096] When the second designated layer is all of the first designated layer, it means that each hot-pressed region of the hot-pressed layer is subjected to thermal crystallization treatment. For example, based on the above-mentioned hot-pressing treatment after every two layers of melt deposition; furthermore, the above-mentioned thermal crystallization treatment is performed after every two layers of hot-pressing treatment.

[0097] When the second designated layer is a portion of the first designated layer, it refers to performing thermal crystallization treatment on a portion of the hot-pressed region of each layer that has undergone hot-pressing treatment. For example, based on the above-mentioned hot-pressing treatment performed after each of every two layers of melt deposition; furthermore, in every 20 layers, the first 6 layers do not undergo thermal crystallization treatment; and in the last 14 layers, each of every two layers undergoes the above-mentioned thermal crystallization treatment after hot-pressing treatment.

[0098] It is understood that the designated area of ​​the hot-pressed region refers to all or part of the hot-pressed region. Performing thermal crystallization treatment on the entire hot-pressed region means performing thermal crystallization treatment on all hot-pressed regions. Performing thermal crystallization treatment on a portion of the hot-pressed region means performing thermal crystallization treatment on only that portion of the hot-pressed region. Furthermore, in the multiple second designated layers, the designated area's proportion of the total area of ​​the hot-pressed region independently ranges from 20% to 100%.

[0099] The aforementioned fused deposition modeling method forms printing sections (i.e., primary crystallization regions) of each layer through fused deposition, and performs hot pressing treatment on the printing section of the first designated layer. This can reduce the gaps between the filaments in the printing section formed by the melting and extruding solidified filaments of the printing nozzle and / or between the printing sections of adjacent layers, which is beneficial to improving the density of the fused deposition modeled component. Then, a designated area of ​​the hot pressing region of the second designated layer is subjected to thermal crystallization treatment. The thermal crystallization treatment step is highly flexible and controllable, and can form secondary crystallization regions with high and uniform crystallinity at fixed points inside the molded component. It works synergistically from multiple aspects of density and crystallinity, which is beneficial to forming fused deposition modeled components with higher strength.

[0100] Furthermore, compared to the technical solution of obtaining a molded component through fused deposition modeling and then forming a highly crystalline layer on the overall surface of the molded component through global heat treatment or surface heat treatment, the above-mentioned fused deposition modeling method is highly operable. The hot pressing crystallization step can adjust the structure and setting position of the secondary crystallization region according to the strength requirements of the fused deposition modeled component. The secondary crystallization region can be the outer periphery or the interior of the printed section, and can form any shape and distribution, with extremely high degree of freedom. Moreover, the hot pressing crystallization step is performed on the printed section, and the hot crystallization treatment step follows the hot pressing treatment step, which can improve the density of the material. Compared with the heat treatment method that acts on the entire component, it can make the density and crystallization degree of the printed section material higher, thereby achieving a higher and more uniform crystallinity and higher material strength.

[0101] The following section will provide a detailed introduction to fused deposition modeling (FDM) additive manufacturing equipment and FDM-formed components, using the FDM method as an example.

[0102] Another embodiment of the present invention provides a fused deposition modeling (FDM) additive manufacturing apparatus, including a fused forming mechanism and a hot pressing crystallization mechanism.

[0103] The melt-forming mechanism is used to melt and deposit raw materials to form the printed cross-sections of each layer. The hot-pressing crystallization mechanism is used to hot-press the printed cross-section of the first designated layer to form the hot-pressed area and to hot-crystallize a designated area of ​​the hot-pressed area of ​​the second designated layer to form the secondary crystallization area.

[0104] Specifically, the melt molding mechanism includes a printing nozzle and a cooling assembly. The printing nozzle is used to melt and extrude the raw material, and the cooling assembly is used to cool the material extruded from the printing nozzle to form the shape. Further, the cooling assembly can be an air-cooled assembly, a water-cooled assembly, etc. The air-cooled assembly includes a fan.

[0105] In some embodiments, the raw material includes polyetheretherketone (PEEK). Unlike ABS and PLA, PEEK is a semi-crystalline thermoplastic material. Whether the polymer chains inside PEEK are arranged in an orderly or disordered manner can be reflected in its macroscopic physical properties. Generally speaking, PEEK material workpieces with orderly arranged polymer chains have high hardness, high strength, and poor toughness, while PEEK material workpieces with disordered polymer chains have good toughness. Therefore, when using PEEK as a raw material, by using the above-mentioned fused deposition modeling method and setting a hot-pressing crystallization step after printing one or more layers, the material density can be improved, and the disordered arrangement of the polymer chains inside PEEK can be transformed into an orderly arrangement, fully utilizing the excellent biocompatibility, high hardness, and high strength advantages of PEEK material workpieces.

[0106] In some embodiments, the PEEK raw material is dried before melt molding. Specifically, drying conditions include drying at a temperature of 60°C to 90°C for 0.5 to 8 hours. In one specific example, the PEEK raw material is PEEK filament with a diameter of 1.75 mm. During melt molding, the PEEK filament is inserted into the inlet of the print head. When the print head reaches the set temperature, it begins to extrude the raw material. A cooling component is used to cool the material extruded from the print head to form the desired shape. Feeding is stopped when the extruded filament is continuous, stable, and free of particulate impurities, thus completing the pre-printing preparation.

[0107] In some embodiments, the melt-forming temperature is 380°C to 420°C. That is, the temperature of the printhead is controlled to be 380°C to 420°C.

[0108] In some embodiments, the diameter of the melt-formed extruded filament is 0.2 mm to 0.4 mm. It is understood that the diameter of the melt-formed extruded filament can be adjusted by the diameter of the nozzle orifice of the printhead. For example, the nozzle orifice diameter may be 0.2 mm or 0.4 mm.

[0109] In some embodiments, the hot-pressing temperature is 135°C to 155°C. Hot-pressing, by controlling the temperature near the glass transition temperature (Tg), presses and flattens the printed cross-section material, thereby reducing or eliminating voids between the filaments in the printed cross-section, thus increasing the density of the fused deposition modeled component, but essentially not changing the degree of crystallinity of the material. Furthermore, this hot-pressing process utilizes the gravity of the heat treatment nozzle itself to press and flatten the material on the printed cross-section, eliminating the need for additional pressure. It is understood that in other examples, hot pressing can also be achieved by applying additional pressure to the heat treatment nozzle as needed.

[0110] like Figure 1 As shown, furthermore, an angle is formed between the printing path 101 used to form the printed cross-section and the hot-pressing path 102 used to form the hot-pressing area. It is understood that the included angle is greater than 0 and less than or equal to 90°, such as 10°, 20°, 30°, 40°, 45°, 50°, 60°, 70°, 80°, or 90°. Optionally, the included angle is 45° to 90°. Forming this angle in this way allows the printed cross-section material to be pressed and flattened more evenly, further reducing or eliminating voids, thereby further improving the density of the fused deposition modeled component. Figure 1 In the specific example shown, the included angle is 90°.

[0111] As an example, the aforementioned hot pressing process can be performed using a heat treatment nozzle. Specifically, the heat treatment nozzle can have the same or similar structure as the printing nozzle and has a heating function, but it does not need to have a discharge port or discharge function. Furthermore, the operating temperature range of both the heat treatment nozzle and the printing nozzle is adjustable from 0 to 500°C. The heat treatment nozzle can also be used simultaneously for thermal crystallization processing, where the operating temperature can be controlled differently from that of the hot pressing process, thus simplifying the equipment.

[0112] It is understood that the heat treatment nozzle serves as a hot-press crystallization mechanism. It is also understood that the aforementioned hot-press treatment and hot-crystallization treatment can be achieved through other hot-press crystallization mechanisms; furthermore, the components for hot-press treatment and hot-crystallization treatment can be implemented using their respective components.

[0113] Furthermore, the diameter of the heat treatment nozzle is 0.1–10 mm, for example, 0.5 mm, 0.8 mm, 1 mm, 1.5 mm, 2 mm, 2.5 mm, 3 mm, 5 mm, 8 mm, or 10 mm. The preferred diameter is 0.5–1 mm.

[0114] Besides the included angle of the heat treatment nozzle, such as Figure 2 As shown, by controlling parameters such as the diameter of the heat treatment nozzle (heating head diameter), the horizontal distance between the heat treatment nozzle and the printing section contour (boundary) (original contour offset), the heat treatment nozzle movement spacing (heating head spacing), and the heat treatment nozzle movement speed, the entire printing section can be uniformly heated, improving the pressing and flattening effect of the printing section material. Taking hot pressing as an example, the heat treatment nozzle movement spacing (heating head spacing) refers to the distance between the centers of the heat treatment nozzles in two adjacent hot pressing paths in the direction perpendicular to the hot pressing path. The heating head movement centerline refers to the movement trajectory of the center of the heat treatment nozzle in the hot pressing path.

[0115] Furthermore, the diameter of the heat treatment nozzle is 0.4 mm to 4 mm.

[0116] It is understood that when the heat treatment nozzle is working, the orthographic projection of the heat treatment nozzle is located within the printing cross-section area. Further, the horizontal distance between the heat treatment nozzle and the printing cross-section profile is 0.2mm to 2mm. Optionally, the horizontal distance between the heat treatment nozzle and the printing cross-section profile can be the radius of the heat treatment nozzle used.

[0117] Furthermore, the movement distance of the heat treatment nozzles is 0.2mm to 6.8mm, so as to maximize the thermal overlap area between two adjacent heat treatment nozzles to account for 30% to 50% of the single heat-affected zone.

[0118] Furthermore, the movement speed of the heat treatment nozzle is 0.1 mm / s to 10 mm / s.

[0119] In some embodiments, the temperature of the thermal crystallization process is 260°C to 320°C.

[0120] Understandably, for the same printed cross-section, hot pressing and thermal crystallization processes can be performed once or multiple times as needed. For example, for the same printed cross-section, the hot pressing process can be performed 2 to 4 times.

[0121] Another embodiment of the present invention provides a fused deposition modeled component, the component being made of polyetheretherketone (PEEK), at least one cross-section of the component including a secondary crystallization region, the crystallinity of the secondary crystallization region being 30%–38%, and the density of the component being ≥1.30 g / cm³. 3 .

[0122] Furthermore, the density of the molded component is 1.30 g / cm³. 3 ~1.35g / cm 3 .

[0123] In some embodiments, in the above-described fused deposition modeling method, after forming the printed cross-sections of each layer, the entire printed cross-section of the first designated layer is subjected to hot pressing to form a hot-pressed region; then, a designated area of ​​the hot-pressed region of the second designated layer is subjected to thermal crystallization to form a secondary crystallization region. Specifically, at least a portion of the second designated layer is controlled to have a designated area surrounding the edge of the hot-pressed region to form an annular region. The printed cross-section thus formed (i.e., a cross-section of the molded component) includes a primary crystallization region that has undergone hot pressing but not thermal crystallization, and a secondary crystallization region surrounding the primary crystallization region to form an annular region; wherein the entire primary crystallization region is also subjected to hot pressing. In other words, the formed printed cross-section includes a hot-pressed region that has not undergone thermal crystallization and a secondary crystallization region surrounding the hot-pressed region to form an annular region; wherein the hot-pressed region is formed by hot pressing the primary crystallization region.

[0124] The crystallinity of the primary crystallization region is lower than that of the secondary crystallization region.

[0125] The resulting molded component has a cross-sectional structure similar to that of the human skeleton, such as... Figure 3 The longitudinal cross-sectional structure and the transverse cross-sectional structure shown in the figure have secondary crystallization regions similar to the cortical bone 201 of human bones and primary crystallization regions similar to the cancellous bone 202 of human bones. This is called a human-like cortical bone and cancellous bone skeletal structure.

[0126] like Figure 4 As shown in the longitudinal and AA cross-sectional views, in a specific example, the molded component is a skull prosthesis, which mimics the structure of human cortical and cancellous bone. This molded component includes an inner layer 110 and an outer layer 120 enclosing the inner layer 110. The outer layer 120 is a secondary crystallization region, and the inner layer 110 is a hot-pressed region formed by hot pressing a primary crystallization region. Further, the thickness of the outer layer 120 is 0.5 mm to 4 mm.

[0127] Furthermore, the crystallinity of the inner layer 110 is 16% to 26%.

[0128] Furthermore, the crystallinity of the outer layer 120 is 30% to 38%.

[0129] Furthermore, the width of the annular region is controlled to be 0.5mm to 4mm, so as to control the thickness of the outer layer 120 to be 0.5mm to 4mm.

[0130] Furthermore, in the second designated layer, the annular region accounts for 20% to 80% of the total area of ​​the hot-pressing region, and can be selected as 30% to 70%. It can be understood that the proportion of the annular region to the total area of ​​the hot-pressing region corresponds to the proportion of the annular region or secondary crystallization region to the area of ​​the corresponding cross-section of the molded component. The total area of ​​the secondary crystallization region can be adjusted as needed, for example, to 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, or 80%.

[0131] Furthermore, in the overall molded component, the secondary crystallization region occupies a volume ratio of 20% to 80%, which can be selected as 30% to 70%.

[0132] In other embodiments, in the above-described fused deposition modeling method, there are multiple designated regions, which are spaced apart on the hot-pressing region. The resulting molded component has at least one printed cross-section, or at least one cross-section of the molded component, comprising a hot-pressed region that has undergone hot pressing but not thermal crystallization, and multiple secondary crystallization regions that have undergone sequential hot pressing and thermal crystallization in the multiple designated regions. These secondary crystallization regions are spaced apart on the cross-section of the molded component and connected by the hot-pressing region. The crystallinity of the hot-pressed region is lower than that of the secondary crystallization regions.

[0133] Furthermore, this application also provides a molded component, wherein at least one printed cross-section or at least one cross-section of the molded component includes a primary crystallization region and a plurality of secondary crystallization regions, the plurality of secondary crystallization regions being spaced apart on the cross-section of the molded component and connected by the primary crystallization region. The crystallinity of the primary crystallization region is lower than that of the secondary crystallization region.

[0134] Thus, multiple spaced secondary crystallization regions can provide strong strength, while the primary crystallization region provides good toughness, thereby enabling the production of molded components with both good pressure resistance and impact resistance. Further hot-pressing the primary crystallization regions to form hot-pressed regions further improves the density of the molded component. Furthermore, the crystallinity of the aforementioned primary crystallization regions or hot-pressed regions is 16%–26%.

[0135] Furthermore, the crystallinity of the aforementioned secondary crystallization region or hot-pressing region is 30% to 38%.

[0136] Furthermore, in multiple second designated layers, the area ratio of the designated region to the primary crystallization region or hot-pressing region is independently 50% to 90%, optionally 60% to 90%. It can be understood that the area ratio of the designated region to the primary crystallization region or hot-pressing region corresponds to the area ratio of the secondary crystallization region to the cross-section in the molded component. The total area of ​​the secondary crystallization region to the cross-section can be adjusted as needed, for example, to 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, or 90%. Further, in the entire molded component, the volume ratio occupied by the secondary crystallization region is 50% to 90%, optionally 60% to 90%.

[0137] Furthermore, the shape of the designated area is not particularly limited; it can be at least one of hexagonal, pentagonal, quadrilateral, triangular, and circular shapes, or it can be an irregular shape. On a cross-section, multiple designated areas can have the same or different shapes and sizes.

[0138] like Figure 5 The cross-section shown has a hexagonal shape in the designated area, and correspondingly, the secondary crystallization area also has a hexagonal shape, forming a molded component that resembles a tortoise shell. For example... Figure 6 As shown, in a specific example, the molded component is a skull prosthesis for the skull, which is a tortoise shell-inspired structure. It can be understood that this molded component is similar to... Figure 5 Any cross-section shown parallel to the cross-section has a similar hexagonal arrangement, resembling a turtle shell.

[0139] Furthermore, the side length of the hexagon is 1mm to 20mm, and can be selected as 2mm to 10mm.

[0140] Furthermore, the hexagon is a regular hexagon.

[0141] Furthermore, the spacing between two adjacent designated areas is 1mm to 10mm, and can be selected as 2mm to 4mm.

[0142] like Figure 7 As shown, the designated area is rectangular, the resulting secondary crystallization area is rectangular, and the formed component is a brick-and-mortar biomimetic structure. For example... Figure 8 As shown, in a specific example, the molded component is a skull prosthesis, which is a brick-and-mortar biomimetic structure.

[0143] Furthermore, the side length of the rectangle is 0.1mm to 100mm, and can be selected as 1mm to 20mm.

[0144] Furthermore, the spacing between two adjacent designated areas is 1mm to 5mm.

[0145] Furthermore, such as Figure 8As shown, the molded component includes a primary crystalline continuous phase and a secondary crystalline reinforcing structure distributed within the primary crystalline continuous phase. The relationship between the continuous phase and the reinforcing structure is similar to that of an "island structure." The secondary crystalline reinforcing structure is a three-dimensional structure, as shown in... Figure 8 In specific examples, it is a cubic structure, such as a cuboid or cube. It is understood that the structure of the secondary crystallization-reinforced structure is not limited to this and can also be other structures.

[0146] Thus, the three-dimensional secondary crystallization reinforced structure can further provide strong strength, while the primary crystallization continuous phase can further provide good toughness, thereby enabling the production of molded components with both good pressure resistance and impact resistance.

[0147] In some embodiments, the fused deposition modeling method described above, after obtaining the molded component by fused deposition, further includes the step of surface roughening at least a portion of the surface of the molded component. Accordingly, at least a portion of the surface of the obtained molded component has a rough surface structure, which is beneficial for cell adhesion when the molded component is used as a prosthesis.

[0148] Furthermore, the surface roughening treatment employs a laser engraving method, using a CO2 laser with a laser density of 2 J / mm². 3 ~20J / mm 3 The distance between the laser and the surface of the component being shaped is 0–40 mm. Laser engraving not only etches a rough, three-dimensional structure onto the surface but also performs a heat treatment to strengthen it. Therefore, the surface of the shaped component after engraving is not only more conducive to cell adhesion but also possesses higher mechanical properties.

[0149] Furthermore, laser engraving is performed under a protective gas atmosphere, which is a non-oxidizing atmosphere, including but not limited to at least one of nitrogen and an inert gas. The inert gas may be at least one of argon and helium. The oxygen content in the protective gas atmosphere is less than 1%. This is because the high temperature during the laser engraving process causes the surface of the PEEK material to undergo an oxidation reaction with oxygen, thereby affecting the performance of the formed component.

[0150] Furthermore, after removing the printed support to obtain the molded component, and before surface roughening, post-processing operations such as grinding and cleaning are included. Cleaning is used to remove organic and inorganic matter from the PEEK workpiece surface. To minimize the impact of impurities embedded in the molded component during subsequent processes on its biocompatibility when used as a prosthesis, an ion gun is used to dry the surface moisture and remove static electricity.

[0151] Accordingly, the aforementioned fused deposition modeling (FDM) additive manufacturing equipment may also include a laser. The laser is used to roughen at least a portion of the surface of the formed component. Further, the laser may be a CO2 laser.

[0152] The main process control parameters for CO2 lasers include laser power, laser scanning speed, and laser spot size. However, compared to traditional chemical etching methods, laser processing is much faster in laser engraving, making the energy density (Ev) crucial, as the process adjustment window is very small. For ease of operation and process stability, the laser density (Ev) can be controlled via [the laser's energy density in J / mm²]. 3 The three-dimensional structure formed by surface roughening treatment is controlled by parameters such as the distance between the laser head and the surface of the component being formed, and the number of processing steps.

[0153] Laser density Ev (J / mm 3 The relationship between the laser power P (J / s), scanning speed V (mm / s), laser spot size D (mm), and laser spacing Δy (mm) is as follows:

[0154] Ev = P / (V*D*△y).

[0155] In some examples, the laser density Ev is 2 J / mm². 3 ~20J / mm 3 The distance between the laser head and the surface of the component being formed is 0–40 mm, preferably 10–30 mm. The number of laser engraving operations can be performed once or multiple times as needed, for example, 1–10 times, with 2–10 times being a possible choice.

[0156] Furthermore, the aforementioned fused deposition modeling additive manufacturing equipment may also include a fixture for holding the shaped component during laser surface roughening treatment.

[0157] Furthermore, the fixture is preferably a fixture with 6 degrees of freedom. Since prostheses and other shaped components are generally irregular curved surfaces, the 6 degrees of freedom of clamping can keep the dynamic distance between the surface of the shaped component being processed and the laser head equal during the laser engraving process, thereby producing a uniform rough surface on the processed surface.

[0158] In a specific example, the multilayer fused deposition modeling step in the above-described fused deposition modeling method can be controlled by a computer program.

[0159] The present invention also provides a computer device, including a memory and a processor, wherein the memory stores a computer program, and the processor executes the computer program to implement the steps of the above-described fused deposition modeling method.

[0160] In some embodiments, the computer device may be a terminal. The computer device includes a processor, memory, network interface, display screen, and input devices connected via a system bus. The processor provides computing and control capabilities. The memory includes non-volatile storage media and internal memory. The non-volatile storage media stores an operating system and computer programs. The internal memory provides an environment for the operation of the operating system and computer programs in the non-volatile storage media. The network interface of the computer device is used to communicate with external terminals via a network connection. When the computer program is executed by the processor, it implements a fused deposition modeling method. The display screen of the computer device may be a liquid crystal display (LCD) or an electronic ink display. The input devices may be a touch layer covering the display screen, buttons, a trackball, or a touchpad mounted on the computer device casing, or an external keyboard, touchpad, or mouse.

[0161] One embodiment of the present invention also provides a computer-readable storage medium having a computer program stored thereon, wherein the computer program, when executed by a processor, implements any of the steps of the above-described fused deposition modeling method.

[0162] Those skilled in the art will understand that all or part of the processes in the methods of the above embodiments can be implemented by a computer program instructing related hardware. The computer program can be stored in a non-volatile computer-readable storage medium. When executed, the computer program can include the processes of the embodiments of the above methods. Any references to memory, storage, databases, or other media used in the embodiments provided by this invention can include non-volatile and / or volatile memory. Non-volatile memory can include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM), or flash memory. Volatile memory can include random access memory (RAM) or external cache memory. By way of illustration and not limitation, RAM is available in various forms, such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), dual data rate SDRAM (DDRSDRAM), enhanced SDRAM (ESDRAM), synchronous link DRAM (SLDRAM), RAMbus direct RAM (RDRAM), direct memory bus dynamic RAM (DRDRAM), and RAMbus dynamic RAM (RDRAM), etc.

[0163] To make the objectives, technical solutions, and advantages of this invention clearer and more concise, the invention is described using the following specific embodiments, but the invention is by no means limited to these embodiments. The embodiments described below are merely preferred embodiments of the invention and can be used to describe the invention, but should not be construed as limiting the scope of the invention. It should be noted that any modifications, equivalent substitutions, and improvements made within the spirit and principles of this invention should be included within the protection scope of this invention.

[0164] To better illustrate the present invention, the following embodiments are provided for further explanation. The specific embodiments are as follows.

[0165] Example 1

[0166] Skull prosthesis with a structure mimicking human cortical and cancellous bone

[0167] 1. Based on the given 3D model of the skull prosthesis, plan the printing section execution program, the compaction region execution program for a specified layer, and the secondary crystallization region execution program for a specified layer in the programming slicing software. Import these printing programs into the device via data cable or USB flash drive for execution. A schematic diagram of the human skeletal structure skull prosthesis and its secondary crystallization region 120 is shown below. Figure 4 As shown in the AA cross-section, it is a printed cross-section. In this embodiment, the average thickness of the prosthesis is 4mm. The secondary crystallization region 120 is set around the edge of the cross-section to form an annular region. The distance between the inner edge and the outer edge of the secondary crystallization region 120 is 1mm (that is, the thickness of the secondary crystallization region 120 on the surface of the prosthesis is 1mm). The secondary crystallization region accounts for 60% of the total volume of the prosthesis.

[0168] 2. Place the 1.75mm diameter PEEK filament raw material into a forced-air drying oven and dry it at 70℃ for 5 hours to thoroughly dry the PEEK raw material.

[0169] 3. Remove the PEEK raw material from the drying oven and insert it into the printhead inlet through the filament threading port. Preheat the printhead in the dual-head printer to 420℃. Once the temperature is reached, set the desired temperature and use the feeding function to extrude the raw material from the printhead. Observe that the extruded filament is continuous, stable, and free of particulate impurities. Stop feeding when the extrusion is complete. The dual-head printer uses a standard printhead with a 0.4mm diameter discharge port. The other printhead, without a discharge port, is for heat treatment (including hot pressing and thermal crystallization), and is defined as the heat treatment printhead with a 1mm diameter.

[0170] 4. After the equipment and program are prepared, the printing program is started to create a skull prosthesis with a biomimetic structure of cortical and cancellous bone. The printing section is printed layer by layer according to the process settings. During the printing process, the fans on both sides of the printing chamber are activated to rapidly cool the freshly extruded PEEK filaments, thus forming a low-crystallinity PEEK material for further processing. During the layer-by-layer printing process, a 140℃ heat treatment nozzle is used to perform hot pressing (i.e., pressing and flattening, the same below) twice within the printed section at a speed of 0.5mm / s in even-numbered layers, deflected by 45°. After the above steps are completed, the heating head temperature is further increased to 300℃, and a secondary crystallization heat treatment (i.e., thermal crystallization, the same below) is performed on the secondary crystallization area planned in step 1 using a heat treatment nozzle at a speed of 1mm / s. The above operation is repeated to obtain a prosthesis with a biomimetic structure. It can be understood that in the first and last few printed sections, thermal crystallization is performed on the entire hot-pressed area, while in the middle section... Figure 4 The AA section shown is a two-dimensional cross-sectional profile where thermal crystallization occurs in the annular region surrounding the hot-pressed region.

[0171] 5. Perform post-processing operations on the completed prosthesis, including removing the printing support, grinding, and cleaning. The cleaning process must thoroughly remove all organic and inorganic matter from the PEEK workpiece surface. Use an ion air gun to dry the surface moisture and remove static electricity to prevent impurities from embedding into the prosthesis during subsequent processes and affecting its biocompatibility.

[0172] 6. Fix the skull prosthesis onto the clamp and place it within the working area of ​​the CO2 laser. Activate the CO2 laser to laser-carve a biocompatible, three-dimensional, roughened surface on the surface of the skull prosthesis in contact with the scalp. The carving process must be performed under the protection of nitrogen gas, with an oxygen content below 1%. The clamp holding the skull prosthesis can move up, down, left, and right, and rotate around the X, Y, and Z axes respectively, ensuring that the dynamic distance between the treated area of ​​the skull prosthesis and the laser head remains equal during the carving process, thus producing a uniformly roughened surface. In this embodiment, the laser density is 5 J / mm². 3 The laser was 25mm away from the surface of the prosthesis, and the processing was performed twice.

[0173] Example 2

[0174] Tortoise shell-like skull prosthesis

[0175] 1. Based on the given 3D model of the skull prosthesis, plan the printing section execution program, the compaction region execution program for a specified layer, and the secondary crystallization region execution program for a specified layer in the programming slicing software. Import these printing programs into the device via data cable or USB flash drive for execution. A schematic diagram of the secondary crystallization region of the tortoise shell-structured skull prosthesis is shown below. Figure 6 As shown. A printed cross-section of the prosthesis is shown. Figure 5 As shown. In this embodiment, the hexagonal side length of the turtle shell biomimetic structure is 10mm, the spacing between each direction of the hexagon is 2mm, and the secondary crystallization region occupies 80% of the overall volume of the prosthesis.

[0176] 2. Place the 1.75mm diameter PEEK filament raw material into a forced-air drying oven and dry it at 70℃ for 5 hours to thoroughly dry the PEEK raw material.

[0177] 3. Remove the PEEK raw material from the drying oven and insert it into the printhead inlet through the filament threading port. Preheat the printhead in the dual-head printer to 410℃. Once the temperature is reached, set the desired temperature and use the feeding function to extrude the raw material from the printhead. Observe that the extruded filament is continuous, stable, and free of particulate impurities. Stop feeding when the extrusion is complete. The dual-head printer uses a standard printhead with a 0.4mm diameter discharge port. The other printhead, without a discharge port, is for heat treatment (including hot pressing and thermal crystallization), and is defined as the heat treatment printhead with a 1mm diameter.

[0178] 4. After the equipment and program are prepared, the printing program is started to create a skull prosthesis with a tortoise shell structure. The printing section is printed layer by layer according to the process settings. During the printing process, fans on both sides of the printing chamber are activated to rapidly cool the freshly extruded PEEK filaments, thus forming a low-crystallinity PEEK material for further processing. During the layer-by-layer printing process, a 145℃ heat treatment nozzle is used to perform two hot-pressing treatments within the printed section at a speed of 0.5 mm / s and a deflection of 90° in even-numbered layers. After the above steps are completed, the heating head temperature is further increased to 310℃, and the secondary crystallization area planned in step 1 is subjected to secondary crystallization heat treatment using the heat treatment nozzle at a speed of 1 mm / s. The above operations are repeated to obtain a prosthesis with a biomimetic structure.

[0179] 5. Perform post-processing operations on the completed prosthesis, including removing the printing support, grinding, and cleaning. The cleaning process must thoroughly remove all organic and inorganic matter from the PEEK workpiece surface. Use an ion air gun to dry the surface moisture and remove static electricity to prevent impurities from embedding into the prosthesis during subsequent processes and affecting its biocompatibility.

[0180] 6. Fix the skull prosthesis onto the clamp and place it within the working area of ​​the CO2 laser. Activate the CO2 laser to laser-carve a biocompatible, three-dimensional, roughened surface on the surface area of ​​the skull prosthesis in contact with the scalp. The carving process must be performed under the protection of an inert argon gas atmosphere with an oxygen content below 1%. The clamp holding the skull prosthesis can move up, down, left, and right, and rotate around the X, Y, and Z axes respectively, ensuring that the dynamic distance between the treated area of ​​the skull prosthesis and the laser head remains equal during the carving process, thus producing a uniformly roughened surface. In this embodiment, the laser density is 4 J / mm². 3 The laser was 20mm away from the surface of the prosthesis, and the processing was performed twice.

[0181] Example 3

[0182] Mud brick biomimetic skull prosthesis

[0183] 1. Based on the given 3D model of the skull prosthesis, plan the printing section execution program, the compaction region execution program for a specified layer, and the secondary crystallization region execution program for a specified layer in the programming slicing software. Import these printing programs into the device via data cable or USB flash drive for execution. A schematic diagram of the secondary crystallization region of the mud-brick biomimetic skull prosthesis is shown below. Figure 7 As shown, one of its printed cross sections is as follows Figure 8 As shown. In this embodiment, the thickness of the skull prosthesis is 4mm, the length * width * height of the "brick" structure is 12mm * 6mm * 4mm respectively, the thickness of the "mud" structure is 2mm, and the secondary crystallization region occupies 85% of the total volume of the prosthesis.

[0184] 2. Place the 1.75mm diameter PEEK filament raw material into a forced-air drying oven and dry it at 70℃ for 5 hours to thoroughly dry the PEEK raw material.

[0185] 3. Remove the PEEK raw material from the drying oven and insert it into the printhead inlet through the filament threading port. Preheat the printhead in the dual-head printer to 420℃. Once the temperature is reached, set the desired temperature and use the feeding function to extrude the raw material from the printhead. Observe that the extruded filament is continuous, stable, and free of particulate impurities. Stop feeding when the extrusion is complete. The dual-head printer uses a standard printhead with a 0.4mm diameter discharge port. The other printhead, without a discharge port, is for heat treatment (including hot pressing and thermal crystallization), and is defined as the heat treatment printhead with a 1mm diameter.

[0186] 4. After the equipment and program are prepared, the printing program is started to produce the mud-brick biomimetic skull prosthesis. The printing section is printed layer by layer according to the process settings. During the printing process, the fans on both sides of the printing chamber are activated to rapidly cool the freshly extruded PEEK filaments, thus forming a low-crystallinity PEEK material for further processing. During the layer-by-layer printing process, a 135℃ heat treatment nozzle is used to perform two hot-pressing treatments within the printed section at a speed of 0.5 mm / s and a deflection of 90° in even-numbered layers. After the above steps are completed, the heating head temperature is further increased to 320℃, and the secondary crystallization area planned in step 1 is subjected to secondary crystallization heat treatment using the heat treatment nozzle at a speed of 1 mm / s. The above operations are repeated to obtain a prosthesis with a biomimetic structure.

[0187] 5. Perform post-processing operations on the completed prosthesis, including removing the printing support, grinding, and cleaning. The cleaning process must thoroughly remove all organic and inorganic matter from the PEEK workpiece surface. Use an ion air gun to dry the surface moisture and remove static electricity to prevent impurities from embedding into the prosthesis during subsequent processes and affecting its biocompatibility.

[0188] 6. Fix the skull prosthesis onto the clamp and place it within the working area of ​​the CO2 laser. Activate the CO2 laser to perform laser engraving on the surface area of ​​the skull prosthesis in contact with the scalp, creating a biocompatible three-dimensional rough surface. The engraving process must be performed under the protection of an inert gas argon, with an oxygen content below 1%. The clamp holding the skull prosthesis can move up, down, left, and right, and rotate around the X, Y, and Z axes respectively, ensuring that the dynamic distance between the treated area of ​​the skull prosthesis and the laser head remains equal during the engraving process, thereby producing a uniformly rough surface. In this embodiment, the laser density is 8 J / mm². 3 The laser was 30mm away from the surface of the prosthesis, and the processing was performed 4 times.

[0189] Comparative Example 1

[0190] The fused deposition model of the skull prosthesis was carried out under the same conditions as in Example 1, that is, the process parameters of the printing nozzle were controlled in the same way. The difference was that the heat treatment nozzle and CO2 laser were not used, that is, the hot pressing treatment and hot crystallization treatment and surface laser engraving treatment in Example 1 were not performed.

[0191] Comparative Example 2

[0192] The molded component obtained in Comparative Example 1 was subjected to surface heating and crystallization treatment at 260°C for 5 seconds using a hot air gun.

[0193] The following are performance tests.

[0194] (I) Scanning Electron Microscopy Test

[0195] 1. Scanning electron microscopy (SEM) was performed on a printed cross-section of Example 1 before hot pressing and after heat treatment but before thermal crystallization. The results are as follows: Figure 9 As shown, a is the sample before hot pressing, and b is the sample after heat treatment but before thermal crystallization.

[0196] This shows that before the hot pressing process, the printed cross-section had many traces of columnar printing paths, with printing gaps between adjacent columnar printing paths. After the heat treatment, the surface was smooth and without printing gaps.

[0197] 2. Scanning electron microscopy (SEM) tests were performed on the skull prosthesis of Example 1 before and after laser engraving, and the results are as follows: Figure 10 As shown, a is a sample magnified 8 times before laser engraving, b is a sample magnified 8 times after laser engraving, and c is a sample magnified 100 times after laser engraving.

[0198] This shows that the surface of the skull prosthesis sample was smooth and flat before laser engraving, but after laser engraving, a large number of micropores appeared on the surface.

[0199] (II) The standards for each performance test are shown in Table 1. Among them, the tensile strength test speed is 50 mm / min, and the bending strength test speed is 2 mm / min.

[0200] The results are shown in Table 1.

[0201] Table 1

[0202]

[0203]

[0204] Note: In Table 1, primary crystallinity refers to the crystallinity of the primary crystallization region, and secondary crystallinity refers to the crystallinity of the secondary crystallization region. In Example 1 and Comparative Examples 1-2, the hardness of the external and internal parts of the implant refers to the hardness of the outer and inner layers of the implant, respectively. For example, in Example 1, these correspond to the hot-pressed region and the secondary crystallization region of the implant, respectively.

[0205] As shown in Table 1, the prosthetic part of Comparative Example 1, which did not undergo hot pressing and thermal crystallization treatment, did not form a biomimetic structure, and did not undergo surface laser engraving treatment, had lower tensile yield strength, tensile fracture strength, bending strength, and cantilever beam notched impact strength compared to the embodiments. The density of the prosthetic part was also lower, and its biocompatibility was also poorer.

[0206] Furthermore, compared to Example 1, Comparative Example 1 also exhibits lower external hardness of its prosthesis.

[0207] Compared to Comparative Example 1, while the heat-treated component of Comparative Example 2 can form secondary crystallization regions on its surface, creating a biomimetic structure, the uneven heating between the surface and interior of the component makes it impossible to accurately control the proportion of the secondary crystallization regions within the prosthesis, nor can it control the uniformity of crystallization within these regions. Furthermore, this heat treatment method easily leads to prosthesis deformation when the prosthesis size is too large. Therefore, although the tensile yield strength, tensile fracture strength, and flexural strength of Comparative Example 2 are improved compared to Comparative Example 1, they are still at a lower level compared to the embodiments. Moreover, the heat treatment method of Comparative Example 2 has poor flexibility and limited applicability. In addition, it is easy to understand that the heat treatment method of Comparative Example 2 cannot manufacture structures with multiple designated regions on the same cross-section, as in Examples 2 and 3.

[0208] Compared with Comparative Examples 1-2, the prosthetic parts prepared in each embodiment have significantly improved tensile yield strength, tensile fracture strength, bending strength, and cantilever beam notched impact strength. Moreover, their secondary crystallinity is much higher than that of the primary crystallinity in Comparative Examples 1-2, indicating that they have better pressure resistance and impact resistance. Furthermore, the rough surface formed by laser engraving is conducive to tissue fixation and cell adhesion, thus improving biocompatibility.

[0209] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0210] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims, and the specification and drawings can be used to interpret the content of the claims.

Claims

1. A fused deposition modeling method, characterized in that, Includes the following steps: Based on the three-dimensional model of the target component, obtain the two-dimensional cross-sectional profile of each slice. Melt deposition is performed within the two-dimensional cross-sectional contour of each layer to form the printed cross-section of each layer, wherein the printed cross-section is a primary crystallization region; Hot pressing is performed on the printed section of the first designated layer to form a hot pressing area; and A thermal crystallization process is performed in a designated area of ​​the hot-pressing region of the second designated layer to form a secondary crystallization region; the second designated layer is all or part of the first designated layer. The raw material for the fused deposition includes polyetheretherketone, the hot pressing temperature is 135℃~155℃, and the thermal crystallization temperature is 260℃~320℃.

2. The fused deposition modeling method as described in claim 1, characterized in that, At least one of the following conditions must be met: (1a) The hot pressing process is performed on the entire printed section of the first specified layer; (1b) The first designated layer is all or part of the printed cross section of each layer; (1c) The designated area of ​​the hot-pressed area is all or part of the hot-pressed area.

3. The fused deposition modeling method as described in claim 2, characterized in that, In at least a portion of the second designated layer, the designated region is arranged around the edge of the hot-pressed region and forms an annular region.

4. The fused deposition modeling method as described in claim 3, characterized in that, The width of the annular region is 0.5mm to 4mm; and / or, In each of the multiple second designated layers, the annular region accounts for 20% to 80% of the area of ​​the hot-pressed region independently.

5. The fused deposition modeling method as described in claim 2, characterized in that, The designated area is multiple, and the multiple designated areas are distributed at intervals on the hot-pressing area.

6. The fused deposition modeling method as described in claim 5, characterized in that, The shape of the designated area is at least one of hexagonal, pentagonal, quadrilateral, triangular, and circular; and / or, In each of the multiple second designated layers, the area of ​​the designated region relative to the area of ​​the hot-pressed region is independently 50% to 90%.

7. The fused deposition modeling method as described in claim 6, characterized in that, In each of the multiple second designated layers, the designated area accounts for 60% to 90% of the area of ​​the hot-pressed area.

8. The fused deposition modeling method as described in claim 6, characterized in that, The designated area is hexagonal in shape; The side length of the hexagon is 1mm to 20mm; and / or, The distance between two adjacent designated areas is 1mm to 10mm.

9. The fused deposition modeling method as described in claim 8, characterized in that, The side length of the hexagon is 2 mm to 10 mm; and / or, The spacing between two adjacent designated areas is 2mm to 4mm.

10. The fused deposition modeling method as described in claim 6, characterized in that, The shape of the designated area is rectangular; The side length of the rectangle is 0.1mm to 100mm; and / or, The spacing between two adjacent designated areas is 1mm to 5mm.

11. The fused deposition modeling method as described in claim 10, characterized in that, The side length of the rectangle is 1mm to 20mm.

12. The fused deposition modeling method according to any one of claims 1 to 11, characterized in that, An angle is formed between the printing path used to form the printed cross section and the hot pressing path used to form the hot pressing area.

13. The fused deposition modeling method as described in claim 12, characterized in that, The included angle is 45°~90°.

14. The fused deposition modeling method according to any one of claims 1 to 11, characterized in that, After the molded component is obtained by fused deposition modeling, the following steps are also included: At least a portion of the surface of the molded component is subjected to surface roughening treatment.

15. The fused deposition modeling method as described in claim 14, characterized in that, The surface roughening treatment is performed using a laser engraving method. The laser is a CO2 laser with a laser density of 2 J / mm³ to 20 J / mm³ and a distance of 0 to 40 mm between the laser and the surface of the formed component.

16. The fused deposition modeling method according to any one of claims 1 to 11, 15, characterized in that, At least one of the following conditions must be met: (2b) The temperature of the molten deposition is 380℃~420℃; (2c) The diameter of the filament extruded by the melt deposition is 0.2 mm to 0.4 mm.

17. A fused deposition modeling additive manufacturing apparatus, characterized in that, include: The melt-forming mechanism is used to melt and deposit raw materials to form printed cross-sections of each layer; and A hot-pressing crystallization mechanism is used to hot-press a printed section of a first specified layer to form a hot-pressed region, and to hot-crystallize a specified area of ​​a hot-pressed region of a second specified layer to form a secondary crystallization region. The second designated layer is all or part of the first designated layer.

18. The fused deposition modeling additive manufacturing apparatus as described in claim 17, characterized in that, The hot-press crystallization mechanism is a heat treatment nozzle.

19. The fused deposition modeling additive manufacturing apparatus according to any one of claims 17-18, characterized in that, The fused deposition modeling (FDM) additive manufacturing apparatus further includes a laser for surface roughening treatment of at least a portion of the surface of the shaped component obtained by the fused deposition modeling mechanism and the hot pressing crystallization mechanism.

20. A computer device comprising a memory and a processor, wherein the memory stores a computer program, characterized in that, When the processor executes the computer program, it implements the steps of the method according to any one of claims 1 to 16.

21. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by a processor, it implements the steps of the method according to any one of claims 1 to 16.

22. A fused deposition modeling component, characterized in that, The molded component is manufactured using the method described in any one of claims 1 to 16.

23. The fused deposition modeled component as claimed in claim 22, characterized in that, At least one cross section of the molded component includes a hot-pressed region and a secondary crystallization region. The secondary crystallization region is arranged around the hot-pressed region and forms an annular region. The hot-pressed region is formed by hot-pressing a primary crystallization region. The crystallinity of the hot-pressed region is lower than that of the secondary crystallization region.

24. The fused deposition modeled component as claimed in claim 23, characterized in that, The fused deposition modeling component includes an inner layer and an outer layer enclosing the inner layer, wherein the outer layer is the secondary crystallization region and the inner layer is a hot-pressed region; and / or, The thickness of the secondary crystallization region is 0.5 mm to 4 mm; and / or, The secondary crystallization region accounts for 20% to 80% of the volume of the fused deposition modeled component.

25. The fused deposition modeled component as claimed in claim 24, characterized in that, The secondary crystallization region accounts for 30% to 70% of the volume of the fused deposition modeled component.

26. The fused deposition modeling component as claimed in claim 22, characterized in that, At least one cross section of the molded component includes a primary crystallization region and a plurality of secondary crystallization regions, the plurality of secondary crystallization regions being distributed at intervals on the cross section and connected through the primary crystallization region, the crystallinity of the primary crystallization region being lower than the crystallinity of the secondary crystallization region.

27. The fused deposition modeled component as claimed in claim 26, characterized in that, The shape of the secondary crystallization region is at least one of hexagonal, pentagonal, quadrilateral, triangular, and circular.

28. The fused deposition modeled component as claimed in claim 27, characterized in that, The secondary crystallization region is hexagonal in shape; The side length of the hexagon is 1mm to 20mm; and / or, The spacing between two adjacent secondary crystallization regions is 1 mm to 10 mm; and / or, The secondary crystallization region accounts for 50% to 90% of the area of ​​the cross section independently.

29. The fused deposition modeled component as claimed in claim 28, characterized in that, The side length of the hexagon is 2 mm to 10 mm; and / or, The spacing between two adjacent secondary crystallization regions is 2mm to 4mm; and / or, The secondary crystallization region accounts for 60% to 90% of the area of ​​the cross section independently.

30. The fused deposition modeling component as claimed in claim 27, characterized in that, The secondary crystallization region is rectangular in shape; The side length of the rectangle is 0.1mm to 100mm; and / or, The spacing between two adjacent secondary crystallization regions is 1 mm to 5 mm; and / or, The secondary crystallization region accounts for 50% to 90% of the area of ​​the cross section independently.

31. The fused deposition modeling component as described in claim 30, characterized in that, The side length of the rectangle is 1mm to 20mm; and / or, The secondary crystallization region accounts for 60% to 90% of the area of ​​the cross section independently.

32. The fused deposition modeled component according to any one of claims 26 to 31, characterized in that, The molded component includes a primary crystalline continuous phase and a secondary crystalline reinforcing structure distributed in the primary crystalline continuous phase.

33. The fused deposition modeled component according to any one of claims 26 to 31, characterized in that, The material of the molded component includes polyetheretherketone, the crystallinity of the secondary crystallization region is 30%~38%, and the density of the molded component is ≥1.30g / cm³.

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