Surface leveling method and 3D printer

Abstract

The application discloses a surface leveling method and a 3D printer. The surface leveling method comprises the following steps: S1, placing a thermoplastic leveling plate on a forming platform; S2, placing an extrusion plate on the thermoplastic leveling plate; S3, heating the thermoplastic leveling plate, the first end surface of the thermoplastic leveling plate is bonded with the forming platform, and the second end surface of the thermoplastic leveling plate is extruded and shaped by an extrusion plane arranged on the extrusion plate; and S4, lowering the temperature of the thermoplastic leveling plate to solidify and form a new forming plane. The application has the advantages of being capable of adjusting and leveling a larger printing area and improving the model printing success rate.

Description

Technical Field

[0001] This invention relates to the field of 3D printer technology, and in particular to leveling technology for molding platforms. Background Technology

[0002] With current technology, leveling the heated bed is an important technique for reducing printing failures in FDM 3D printers.

[0003] A heated bed, also known as a forming platform, has many leveling techniques:

[0004] 1. Four height adjustment screws are installed at the bottom of the heated bed. Leveling is achieved by turning the adjustment screws.

[0005] 2. Leveling is achieved by detecting the height of several hotbed locations using leveling sensors, and then using algorithms for compensation. Leveling sensors come in many different types.

[0006] Both adjusting screws and using leveling sensors to collect data and then compensate for leveling have the following problems: Because the heated bed is not a perfect plane, it has many uneven areas, and these locations are uncertain. Adjusting screws can only level four points, not the middle or other points on the heated bed. Furthermore, larger adjustments make the heated bed more prone to deformation due to pressure; typically, heated beds are very thin. Using leveling sensors can only collect height data from a limited number of points, meaning leveling is still done in a fuzzy manner. Leveling fails when there are sudden changes in height between two adjacent data points. Especially when printing the first layer at these leveling failure locations, the first layer may not stick to the heated bed, leading to printing failures.

[0007] Currently, FDM printers mainly use two structural designs. The first type is exemplified by Chinese patent application number CN201410083890.7, entitled "FDM Technology 3D Printer." The second type is exemplified by Chinese patent application number CN201720109614.2, entitled "A 3D Printer." Summary of the Invention

[0008] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a surface leveling method and a 3D printer, which has the advantages of being able to adjust a larger printing area to be flat and improving the success rate of model printing.

[0009] The technical solution adopted in this invention is:

[0010] The surface leveling method includes the following steps:

[0011] S1. Place a thermoplastic molding plate on the molding platform. The thermoplastic molding plate has a first end face and a second end face. The first end face of the thermoplastic molding plate is in contact with the molding platform.

[0012] S2. Place an extrusion plate on a thermoplastic mixing plate. The extrusion plate has an extrusion plane. The second end face of the thermoplastic mixing plate is in contact with the extrusion plane of the extrusion plate.

[0013] S3. The thermoplastic sheet is heated, and at the same time the thermoplastic sheet is subjected to the extrusion pressure of the extrusion plate and the forming platform; after the thermoplastic sheet is heated and melted, the first end face of the thermoplastic sheet is bonded to the forming platform, and the second end face of the thermoplastic sheet is subjected to the extrusion shaping by the extrusion plane set by the extrusion plate.

[0014] S4. The temperature of the thermoplastic platen is lowered to solidification, and the second end face of the thermoplastic platen forms a new molding plane that matches the extrusion plane.

[0015] The principle is as follows: The thermoplastic sheet is softened by heating. Pressure is then applied to the thermoplastic sheet placed on the forming platform, shaping the softened sheet. The temperature of the thermoplastic sheet is then lowered until it cools and solidifies, forming a new molded surface. The flatness of this new molded surface is the same as the extruded surface. In other words, the extruded surface serves as the reference plane, used to shape the second end face of the thermoplastic sheet. This significantly reduces the likelihood of leveling failures due to unevenness in multiple locations on the forming platform.

[0016] In step S3, heat is transferred from the molding platform and / or the extrusion plate to the thermoplastic leveling plate. Preferably, a heater is installed on the molding platform. To accelerate the leveling process, heaters are installed on both the molding platform and the extrusion plate, meaning the thermoplastic leveling plate is heated both above and below, allowing for softening of the thermoplastic leveling plate in a shorter time.

[0017] The thermoplastic liner is made of the same material as the FDM 3D printing filament. Examples include PLA 3D printing filament, PTU 3D printing filament, ABS 3D printing filament, etc. This means that when the first layer of printing begins, the closer / identical nature of the material results in better adhesion, increasing the success rate of model printing.

[0018] The peeling force required to separate the first end face of the thermoplastic molding plate from the forming platform is greater than the peeling force required to separate the second end face of the thermoplastic molding plate from the extrusion surface of the extrusion plate. This is because the extrusion plate needs to be peeled apart while the first end face remains adhered to the forming platform.

[0019] The roughness of the extrusion surface of the extrusion plate is less than that of the forming platform.

[0020] The extrusion surface of the extrusion plate is provided with a layer of hydrophobic material.

[0021] Furthermore, the hydrophobic material layer can be any one of a Teflon material layer, a marble material layer, a stainless steel material layer, or an aluminum alloy material layer.

[0022] Furthermore, the hydrophobic material layer is an oil layer coated on the extrusion surface.

[0023] There are two approaches to applying surface leveling methods to 3D printers. They are:

[0024] The first solution involves a 3D printer employing the aforementioned surface leveling method. The 3D printer includes a frame, a Y-axis moving device mounted on the frame, a forming platform mounted on the Y-axis moving device, a thermoplastic leveling plate placed on the forming platform, an extrusion plate positioned above the thermoplastic leveling plate, a Z-axis lifting device, a heater, and a controller. The extrusion plate is mounted on the Z-axis lifting device. The controller is electrically connected to the Y-axis moving device, the Z-axis lifting device, and the heater. The heater is mounted on the forming platform or on the extrusion plate. This solution primarily involves the forming platform being mounted on the Y-axis. The Z-axis lifting device drives the X-axis moving device, which in turn mounts the extrusion plate onto the X-axis moving device, indirectly mounting the extrusion plate onto the Z-axis lifting device. The controller controls the Z-axis lifting device to descend, which in turn drives the X-axis moving device to descend. As the X-axis moving device descends, it drives the extrusion plate to descend, extruding the thermoplastic leveling plate. Because the Y-axis moving device remains stationary, the extrusion plate shapes the second end face after the thermoplastic leveling plate softens. After the thermoplastic leveling plate cools and solidifies, the second end face is formed, achieving the leveling process.

[0025] The second solution involves a 3D printer that employs the aforementioned surface leveling method. The 3D printer includes a frame, a Z-axis lifting device fixedly mounted on the frame, a forming platform fixedly mounted on the Z-axis lifting device, a thermoplastic adjustment plate placed on the forming platform, an extrusion plate positioned above the thermoplastic adjustment plate, a heater, and a controller. The controller is electrically connected to both the Z-axis lifting device and the heater. The heater is mounted on the forming platform or on the extrusion plate. The extrusion plate is connected to the frame via a height-limiting component. The key difference in this solution is that the forming platform is mounted on the Z-axis.

[0026] Furthermore, the height-limiting component includes through holes at both ends of the extrusion plate, two nuts and two screws mounted on the frame. The two screws are located at both ends of the extrusion plate, with each screw passing through a through hole and mounted on one of the nuts. The main mechanism involves a Z-axis lifting device that drives the forming platform upwards, thereby pushing the thermoplastic leveling plate against the extrusion plate to achieve the extrusion purpose. Once the thermoplastic leveling plate softens, it can be shaped; after cooling, it solidifies and sets, achieving the leveling objective.

[0027] Whether it's the first or the second option, thermoplastic flat plates have a higher success rate when printing the first layer of the model because the material is similar to or the same as the material of 3D printing consumables.

[0028] The beneficial effects of this invention are: it has the advantages of being able to adjust a larger printing area to be flat and improving the success rate of model printing. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the molding platform in this invention;

[0030] Figure 2 This is a schematic diagram illustrating the process of placing a thermoplastic sheet onto a molding platform in this invention.

[0031] Figure 3 This is a schematic diagram illustrating the effect of placing the thermoplastic molding plate on the molding platform in this invention;

[0032] Figure 4 This is a schematic diagram illustrating the principle of placing the extrusion plate onto the thermoplastic molding plate in this invention.

[0033] Figure 5 This is a schematic diagram showing the effect of stacking the molding platform, thermoplastic mixing plate, and extrusion plate in this invention;

[0034] Figure 6 This is a schematic diagram of the pressure exerted by the forming platform and the extrusion plate on the thermoplastic plate in this invention.

[0035] Figure 7 This is a schematic diagram of the cross-sectional structure of an uneven forming platform, according to one embodiment of the present invention.

[0036] Figure 8 yes Figure 7 A schematic diagram illustrating the cross-sectional principle of placing the thermoplastic sheet and extrusion plate;

[0037] Figure 9 yes Figure 8 A schematic diagram of the cross-sectional principle of a thermoplastic flat plate that is deformed by the extrusion pressure of a forming platform and an extrusion plate after being heated and softened by heat.

[0038] Figure 10 yes Figure 9 A schematic diagram illustrating the cross-sectional principle of a thermoplastic sheet after it has been shaped, cooled, and solidified, with the extrusion plate removed; mainly used to show the formation of a new shaped plane;

[0039] Figure 11 yes Figure 10 Based on this, a schematic diagram of the cross-sectional structure principle of the hydrophobic material layer is shown;

[0040] Figure 12 This is a schematic diagram of the actual structural principle of an extrusion plate using the first embodiment of the present invention;

[0041] Figure 13 This is a schematic diagram of the structural principle of the first scheme adopted in this invention;

[0042] Figure 14 This is a schematic diagram of a certain embodiment of the extrusion plate in the second scheme of the present invention;

[0043] Figure 15 This is a schematic diagram of the structural principle of the second scheme adopted in this invention. Detailed Implementation

[0044] like Figures 1 to 15 As shown, the surface leveling method of the present invention includes the following steps:

[0045] S1. Place a thermoplastic molding plate 2 on the molding platform 1. The thermoplastic molding plate 2 has a first end face 21 and a second end face 22. The first end face 21 of the thermoplastic molding plate 2 is in contact with the molding platform 1.

[0046] S2. Place an extrusion plate 3 on the thermoplastic plate 2. The extrusion plate 3 has an extrusion plane 31. The second end face 22 of the thermoplastic plate 2 is in contact with the extrusion plane 31 of the extrusion plate 3.

[0047] S3. The thermoplastic plate 2 is heated, and at the same time, the thermoplastic plate 2 receives the extrusion pressure from the extrusion plate 3 and the forming platform 1. After the thermoplastic plate 2 is heated and melted, the first end face 21 of the thermoplastic plate 2 is bonded to the forming platform 1, and the second end face 22 of the thermoplastic plate 2 is extruded and shaped by the extrusion plane 31 provided by the extrusion plate 3.

[0048] S4. The temperature of the thermoplastic plate 2 is lowered to solidification, and the second end face 22 of the thermoplastic plate 2 forms a new molding plane that matches the extrusion plane 31.

[0049] The principle is as follows: The thermoplastic sheet is softened by heating. Pressure is then applied to the thermoplastic sheet placed on the forming platform, shaping the softened sheet. The temperature of the thermoplastic sheet is then lowered until it cools and solidifies, forming a new molded surface. The flatness of this new molded surface is the same as the extruded surface. In other words, the extruded surface serves as the reference plane, used to shape the second end face of the thermoplastic sheet. This significantly reduces the likelihood of leveling failures due to unevenness in multiple locations on the forming platform.

[0050] In step S3, heat is transferred from the molding platform 1 and / or the extrusion plate 3 to the thermoplastic molding plate 2.

[0051] Preferably, the heater is installed on the molding platform. To improve the heating and leveling speed, heaters are installed on both the molding platform and the extrusion plate, meaning that the thermoplastic flat plate is heated from both above and below, allowing the thermoplastic flat plate to soften in a shorter time.

[0052] The thermoplastic liner is made of the same material as the FDM 3D printing filament. Examples include PLA 3D printing filament, PTU 3D printing filament, ABS 3D printing filament, etc. This means that when the first layer of printing begins, the closer / identical nature of the material results in better adhesion, increasing the success rate of model printing.

[0053] The peeling force required to separate the first end face 21 of the thermoplastic molding plate 2 from the molding platform 1 is greater than the peeling force required to separate the second end face 22 of the thermoplastic molding plate 2 from the extrusion plane 31 of the extrusion plate 3.

[0054] The roughness of the extrusion plane 31 of the extrusion plate 3 is less than the roughness of the forming platform 1.

[0055] The extrusion plane 31 of the extrusion plate 3 is provided with a layer of hydrophobic material 32.

[0056] The hydrophobic material layer 32 can be any one of the following: Teflon material layer, marble material layer, stainless steel material layer, and aluminum alloy material layer.

[0057] The hydrophobic material layer 32 is an oil layer coated on the extrusion plane 31.

[0058] The first solution involves a 3D printer employing the aforementioned surface leveling method. The 3D printer 4 includes a frame 41, a Y-axis moving device 42 mounted on the frame 41, a forming platform 1 mounted on the Y-axis moving device 42, a thermoplastic leveling plate 2 placed on the forming platform, an extrusion plate 3 positioned above the thermoplastic leveling plate 2, a Z-axis lifting device 43, a heater 44, and a controller 45. The extrusion plate 3 is mounted on the Z-axis lifting device 43. The controller 45 is electrically connected to the Y-axis moving device 42, the Z-axis lifting device 43, and the heater 44. The heater 44 is mounted on the forming platform 1 or on the extrusion plate 3. In this solution, the forming platform is mounted on the Y-axis, and the Z-axis lifting device drives the X-axis moving device, thus indirectly mounting the extrusion plate on the Z-axis lifting device. The controller controls the Z-axis lifting device to descend, which in turn drives the X-axis moving device to descend. As the X-axis moving device descends, it drives the extrusion plate to descend, extruding the thermoplastic leveling plate. Because the Y-axis moving device remains stationary, the extrusion plate shapes the second end face after the thermoplastic adjusting plate softens. Once the thermoplastic adjusting plate cools and solidifies, the second end face is formed, achieving the leveling process. The extrusion plate can be bolted to the X-axis moving device driven by the Z-axis lifting device.

[0059] The second solution: a 3D printer, which employs the aforementioned surface leveling method. The 3D printer 4 includes a frame 46, a Z-axis lifting device 43 fixedly mounted on the frame 46, a forming platform 1 fixedly mounted on the Z-axis lifting device 43, a thermoplastic leveling plate 2 placed on the forming platform 1, an extrusion plate 3 positioned above the thermoplastic leveling plate 2, a heater 44, and a controller 45. The controller 45 is electrically connected to both the Z-axis lifting device 43 and the heater 44. The heater 44 is mounted on the forming platform or on the extrusion plate 3. The extrusion plate 3 is connected to the frame 46 via a height limiting component 47. The main difference in this solution is that the forming platform is mounted on the Z-axis.

[0060] Furthermore, the height-limiting component includes through holes at both ends of the extrusion plate, two nuts and two screws mounted on the frame. The two screws are located at both ends of the extrusion plate, with each screw passing through a through hole and mounted on one of the nuts. The main mechanism involves a Z-axis lifting device that drives the forming platform upwards, thereby pushing the thermoplastic leveling plate against the extrusion plate to achieve the extrusion purpose. Once the thermoplastic leveling plate softens, it can be shaped; after cooling, it solidifies and sets, achieving the leveling objective.

[0061] Whether it's the first or the second option, thermoplastic flat plates have a higher success rate when printing the first layer of the model because the material is similar to or the same as the material of 3D printing consumables.

[0062] The beneficial effects of this invention are: it has the advantages of being able to adjust a larger printing area to be flat and improving the success rate of model printing.

Claims

1. A surface leveling method, characterized in that... Includes the following steps: S1. Place a thermoplastic sizing plate (2) on the molding platform (1). The thermoplastic sizing plate (2) is made of the same or similar thermoplastic material as the FDM 3D printing consumable. The thermoplastic sizing plate (2) has a first end face (21) and a second end face (22). The first end face (21) of the thermoplastic sizing plate (2) is in contact with the molding platform (1). S2. Place an extrusion plate (3) on the thermoplastic plate (2). The extrusion plate (3) has an extrusion plane (31). The second end face (22) of the thermoplastic plate (2) is in contact with the extrusion plane (31) of the extrusion plate (3). S3. The thermoplastic plate (2) is heated, and at the same time, the thermoplastic plate (2) receives the extrusion pressure from the extrusion plate (3) and the molding platform (1); after the thermoplastic plate (2) is heated and melted, the first end face (21) of the thermoplastic plate (2) is bonded to the molding platform (1), so that the thermoplastic plate (2) and the molding platform (1) become one piece, and the second end face (22) of the thermoplastic plate (2) is extruded and shaped by the extrusion plane (31) provided by the extrusion plate (3), and the extrusion and shaping makes all the printing areas of the thermoplastic plate (2) flattened; S4. The temperature of the thermoplastic plate (2) is lowered to solidification, and the second end face (22) of the thermoplastic plate (2) forms a new molding plane that matches the extrusion plane (31). The new molding plane serves as the printing base surface of the first layer of 3D printing, so that the first layer printing material has good adhesion compatibility with the new molding plane.

2. The surface leveling method according to claim 1, characterized in that: In step S3, heat is transferred from the molding platform (1) and / or the extrusion plate (3) to the thermoplastic molding plate (2).

3. The surface leveling method according to claim 1, characterized in that: The peeling force required to separate the first end face (21) of the thermoplastic adjusting plate (2) from the molding platform (1) is greater than the peeling force required to separate the second end face (22) of the thermoplastic adjusting plate (2) from the extrusion plane (31) of the extrusion plate (3), so that when the extrusion plate (3) is removed after step S4, the thermoplastic adjusting plate (2) and the molding platform (1) remain as a whole without separation.

4. The surface leveling method according to claim 1, characterized in that: The roughness of the extrusion plane (31) of the extrusion plate (3) is less than that of the forming platform (1).

5. The surface leveling method according to claim 1, characterized in that: The extrusion plane (31) of the extrusion plate (3) is provided with a layer of hydrophobic material (32).

6. The surface leveling method according to claim 5, characterized in that: The hydrophobic material layer (32) is any one of the following: Teflon material layer, marble material layer, stainless steel material layer, and aluminum alloy material layer.

7. The surface leveling method according to claim 5, characterized in that: The hydrophobic material layer (32) is an oil layer coated on the extrusion plane (31).

8. A 3D printer that employs the surface leveling method as described in any one of claims 1 to 7, characterized in that: The 3D printer (4) includes a frame (41), a Y-axis moving device (42) mounted on the frame (41), a forming platform (1) mounted on the Y-axis moving device (42), a thermoplastic adjustment plate (2) placed on the forming platform, an extrusion plate (3) located above the thermoplastic adjustment plate (2), a Z-axis lifting device (43), a heater (44), and a controller (45); the extrusion plate (3) is mounted on the Z-axis lifting device (43); the controller (45) is electrically connected to the Y-axis moving device (42), the Z-axis lifting device (43), and the heater (44); the heater (44) is mounted on the forming platform (1) or on the extrusion plate (3).

9. A 3D printer that employs the surface leveling method as described in any one of claims 1 to 7, characterized in that: The 3D printer (4) includes a frame (46), a Z-axis lifting device (43) fixedly mounted on the frame (46), a forming platform (1) fixedly mounted on the Z-axis lifting device (43), a thermoplastic adjustment plate (2) placed on the forming platform (1), an extrusion plate (3) located above the thermoplastic adjustment plate (2), a heater (44) and a controller (45); the controller (45) is electrically connected to the Z-axis lifting device (43) and the heater (44); the heater (44) is mounted on the forming platform or on the extrusion plate (3); the extrusion plate (3) is connected to the frame (46) through a height limiting component (47).

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