An optimization method for preparing 3D printing PEEK gas cylinder based on FDM process

Abstract

The application belongs to the technical field of 3D printing, and particularly discloses an optimization method for preparing a 3D printing PEEK gas cylinder based on an FDM process, which comprises a control module, a motion module, a feeding module, a melt extrusion module and a forming module. The optimization method for preparing a 3D printing PEEK gas cylinder based on an FDM process sets the control module, controls and adjusts the printing process in real time by using the control system in the control module, sets the temperature sensor in the melt extrusion module to be connected with the control module, measures the melt temperature in real time by the temperature sensor and transmits the melt temperature to the control module, controls the heating module to adjust the melt temperature in real time by the system measurement result in the control module, so that the printed PEEK material is always melted at a suitable temperature, the temperature is prevented from being too high to cause polymer crosslinking or degradation, and the forming quality of the PEEK material is prevented from being affected, and the control module controls the conveying speed and other parameters of the feeding module in the process of PEEK forming.

Description

Technical Field

[0001] This invention relates to the field of 3D printing technology, specifically to an optimized method for preparing 3D printed PEEK gas cylinders based on FDM technology. Background Technology

[0002] Additive manufacturing technology, also known as 3D printing, is a type of rapid prototyping technology. It utilizes three-dimensional digital modeling technology, using software to slice any desired structure and then layering the material through a CNC forming system to create the final product. It features integrated processing, diverse structural manufacturing, and assembly-free integral molding. After years of development, 3D printing technology has gradually become a research hotspot and important track in high-end manufacturing, with wide applications in biomedicine, aerospace, transportation, machinery manufacturing, and the food industry. 3D printing technology mainly includes photopolymerization, selective laser sintering, fused deposition modeling (FDM), and binder jetting. FDM involves heating filaments of thermoplastic polymer materials, such as PA, ABS, and PLA, or low-melting-point metals to a molten state, then extruding them through a nozzle under program control and stacking them layer by layer according to a printing path set based on the digital model slices to create a three-dimensional product. Equipment suitable for this technology has a simple structure, low cost, stable operation, and low pollution; therefore, FDM has become the most widely used technology in the additive manufacturing field.

[0003] Polyetheretherketone (PEEK) is a high-molecular-weight polymer material with excellent overall properties. PEEK has a thermal decomposition temperature above 500℃ and can be used for extended periods at 260℃ while maintaining good thermal stability. The molecular structure of PEEK contains numerous rigid benzene rings and ketone bonds, while the ether bonds provide it with a certain degree of toughness. The combined effect of these two structures gives PEEK materials excellent strength, modulus, and toughness, allowing it to maintain its room-temperature mechanical properties in environments ranging from -65℃ to 260℃. In addition, PEEK also possesses excellent dimensional stability, superior wear resistance, excellent flame retardancy, excellent chemical corrosion resistance, and other superior properties. Therefore, PEEK materials are widely used, and the use of FDM technology to prepare PEEK products is currently a hot topic.

[0004] Due to the inherent defects in the FDM molding principle, the performance of finished products formed by FDM process exhibits obvious anisotropy, especially low interlayer shear strength. The surface steps formed by the stacking of molten filaments affect both visual aesthetics and molding accuracy. Therefore, there is a need to improve the process method for preparing PEEK gas cylinders based on FDM technology. Summary of the Invention

[0005] The purpose of this invention is to provide an optimized method for preparing 3D printed PEEK gas cylinders based on FDM technology, so as to solve the problems mentioned in the background art, such as low interlayer shear strength and molding accuracy of PEEK gas cylinders due to defects in FDM process.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an optimized method for preparing 3D printed PEEK gas cylinders based on FDM process, comprising a control module, a motion module, a feeding module, a melt extrusion module, and a forming module, wherein the control module is connected to the motion module, the feeding module, the melt extrusion module, and the forming module respectively, and controls the operation of each module;

[0007] The motion module is connected to the feeding module, the melt extrusion module, and the forming module, and drives the module to move.

[0008] Preferably, the feeding module is equipped with a wire feeding wheel to continuously and quantitatively transport the raw materials to the melt extrusion module.

[0009] Using the above technical solution, the raw material is continuously and quantitatively conveyed to the melt extrusion module of the FDM molding equipment by the wire feeding wheel set in the feeding module for extrusion molding.

[0010] Preferably, the melt extrusion module includes a heating module, a throat, a melt nozzle, and a temperature sensor. The heating module is controlled by a control module, the heating module is connected to the throat, the throat is connected to the melt nozzle, and the temperature sensor is connected to the control module.

[0011] Using the above technical solution, the printing raw material input by the feeding module is heated to a molten state in the throat by the heating module and then extruded through the melt nozzle. At the same time, the temperature sensor measures the melt temperature and transmits it to the control module. The control module controls the heating module to adjust the melt temperature according to the measurement results, so that the printing raw material melts at a suitable temperature, avoiding excessive temperature that may cause polymer cross-linking or degradation, thereby affecting the molding quality.

[0012] Preferably, the molding module is provided with a molding base plate, which supports the melt molding process.

[0013] Using the above technical solution, the melt is extruded from the nozzle of the melt extrusion module and falls onto the molding base plate, gradually cooling down and becoming solid, thus carrying out the molding process.

[0014] Preferably, the set temperature of the molding space within the molding module is higher than the glass transition temperature of the PEEK material, which is 143°C.

[0015] Using the above technical solution, PEEK material can more easily crystallize in an environment above room temperature, improving the strength of the molded body. Setting the temperature above the glass transition temperature of PEEK material results in a lighter molded body.

[0016] Preferably, the parameters of the melt extrusion module are set as follows:

[0017] The melt nozzle extrusion layer height is set to 0.2mm, the line width is set to 0.4mm, the initial layer height is set to 0.15mm, and the initial layer line width is set to 100%.

[0018] The melt nozzle extrusion wall thickness is set to 1.2mm, the number of wall lines is set to 3, the outer wall is embedded 0.2mm, the outer wall is filled first and then the inner wall, the gap between the inner and outer walls is filled completely, and the Z-slits are aligned.

[0019] The fill density is set to 100%, the fill trace distance is 0.4mm, the fill pattern is a straight line, the fill trace multiplier is 1, the fill overlap percentage is 10%, and the fill overlap is 0.04mm.

[0020] The flow rate is set to 100%, and the initial layer flow rate is 100%.

[0021] The filling speed is set to 25 mm / s, the outer wall speed is set to 25 mm / s, the inner wall speed is set to 30 mm / s, the empty running speed is set to 80 mm / s, and the initial layer speed is set to 22.5 mm / s.

[0022] By adopting the above technical solution, compared with the current parameter settings, this solution adjusts the filling overlap percentage from 5% to 10% and the filling overlap from 0.02mm to 0.04mm, reduces the filling speed, avoids partial cavitation in the PEEK cylinder body due to imperfect interlayer fusion bonding, and increases the strength of the PEEK cylinder.

[0023] Preferably, the process for fabricating 3D-printed PEEK gas cylinders using the FDM process is as follows:

[0024] The gas cylinder was designed and modeled, and the model was processed using Cura slicing software to obtain slice data;

[0025] Fix the printing substrate by placing it on the molding base plate and fixing it with a fixing device;

[0026] Adjust the gap between the print nozzle and the sticker, set the Z-axis distance to the negative limit, then turn the leveling knob for coarse adjustment. Adjust the gap between the print nozzle and the sticker to between 0.1mm and 0.2mm, perform a test print, and make fine adjustments again based on the print results.

[0027] Set the melt heating module and hopper temperature, and set the printing nozzle temperature to 420℃ and the wire and hopper heating temperature to 100℃.

[0028] For the PEEK melt test print, once the print nozzle temperature reaches 420℃, click "feed" on the manual interface screen and observe whether the PEEK filament is flowing smoothly out of the print head. Proceed to the next step once the filament is flowing smoothly.

[0029] Slice data selection and reading: Import the model's slice data into the device, enter the control program's printing page, select and read the corresponding file, and set the printing parameters:

[0030] Once the parameters are confirmed to be correct, printing can begin.

[0031] Remove the molded body. After printing is complete, remove the fully printed molded body from the molding base plate.

[0032] Post-processing of gas cylinders involves polishing, grinding, and annealing the printed PEEK gas cylinder semi-finished products to obtain the finished PEEK gas cylinders.

[0033] By adopting the above technical solution and changing the PEEK melt printing parameters, the finished PEEK cylinder has higher strength and can also avoid the formation of air pockets.

[0034] Compared with the prior art, the beneficial effects of this invention are: an optimized method for fabricating 3D-printed PEEK gas cylinders based on FDM technology.

[0035] 1. In this invention, a control module is set up, and the control system in the control module controls and adjusts the printing process in real time. A temperature sensor is set in the melt extrusion module and connected to the control module. The temperature sensor measures the melt temperature in real time and transmits it to the control module. The system measurement results in the control module control the heating module to adjust the melt temperature in real time, so that the printed PEEK material always melts at a suitable temperature, avoiding excessive temperature from causing polymer cross-linking or degradation, which would affect the molding quality of the PEEK material. During the PEEK molding process, the control module also controls the conveying speed and other parameters of the feeding module, so that the PEEK material remains under control during the molding process, thereby increasing the quality of the finished PEEK cylinder.

[0036] 2. In this invention, an FDM device with a high-temperature chamber environment is used to form PEEK material. The forming environment, which is higher than room temperature, is conducive to the fusion of the melts, thereby improving the bonding strength of the formed body in the Z direction. Compared with the current parameter settings, the parameter settings in this invention adjust the fill overlap percentage from 5% to 10%, the fill overlap from 0.02mm to 0.04mm, and at the same time reduce the filling speed, thereby avoiding the occurrence of cavitation in the bottle body due to poor interlayer fusion bonding. After FDM printing according to the adjusted parameters, the interlayer fusion bonding of the finished PEEK gas cylinder body is good, and the cavitation phenomenon is significantly improved. Attached Figure Description

[0037] Figure 1 This is a schematic diagram showing the connections between the various modules of the present invention;

[0038] Figure 2 This is a schematic diagram of the melt control module of the present invention;

[0039] Figure 3 This is a schematic diagram of the process flow of the present invention. Specific implementation methods

[0040] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0041] Please see Figure 1-3 The present invention provides a technical solution: an optimized method for preparing 3D printed PEEK gas cylinders based on FDM process.

[0042] The control module is connected to the motion module, feeding module, melt extrusion module, and forming module, controlling the operation of each module. The motion module is connected to the feeding module, melt extrusion module, and forming module, driving the module's movement. The feeding module is equipped with a feeding wheel to continuously and quantitatively deliver raw materials to the melt extrusion module. The melt extrusion module includes a heating module, a throat, a melt nozzle, and a temperature sensor. The heating module is controlled by the control module and is connected to the throat, which is connected to the melt nozzle. The temperature sensor is connected to the control module. The forming module is equipped with a forming base plate, which supports the melt forming process. The set temperature of the forming space within the forming module is higher than the glass transition temperature of PEEK material. The glass transition temperature of material K is 143℃. The parameters of the melt extrusion module are set as follows: melt nozzle extrusion layer height is set to 0.2mm, line width is set to 0.4mm, initial layer height is set to 0.15mm, and initial layer line width is set to 100%; melt nozzle extrusion wall thickness is set to 1.2mm, wall line count is set to 3, outer wall embedment is 0.2mm, outer wall first then inner wall, the gap between the inner and outer walls is set to be fully filled, and Z-seam alignment is set; filling density is set to 100%, filling line distance is 0.4mm, filling pattern is straight line, filling line multiplier is 1, filling overlap percentage is 10%, and filling overlap is 0.04mm; flow rate is set to 100%, and initial layer flow rate is 100%.

[0043] The filling speed is set to 25 mm / s, the outer wall speed to 25 mm / s, the inner wall speed to 30 mm / s, the empty running speed to 80 mm / s, and the initial layer speed to 22.5 mm / s. The process for fabricating a 3D printed PEEK gas cylinder using FDM technology is as follows: The gas cylinder is designed and modeled, and the model is processed using Cura slicing software to obtain slicing data; the printing substrate is fixed by placing it on the molding base plate and securing it with a fixing device.

[0044] Adjust the gap between the print nozzle and the sticker. Set the Z-axis distance to the negative limit, then turn the leveling knob for coarse adjustment, adjusting the gap between the print nozzle and the sticker to between 0.1mm and 0.2mm. Perform a test print, and fine-tune again based on the print results. Set the melt heating module and hopper temperature, setting the print nozzle temperature to 420℃ and the filament and hopper heating temperatures to 100℃. Perform a PEEK melt test print. Once the print nozzle temperature reaches 420℃, click on the manual interface operation screen. Feeding the filament: Observe whether the PEEK filament is flowing smoothly from the print head. Proceed to the next step once the filament is flowing smoothly. Slice data selection and reading: Import the slice data of the model into the device, enter the control program printing page, select the corresponding file and read it, and set the printing parameters. Printing: After confirming that the parameter settings are correct, start printing. Removing the molded body: After printing, remove the fully printed molded body from the molding base plate. Gas cylinder post-processing: Polish and anneal the printed PEEK gas cylinder semi-finished product to obtain the finished PEEK gas cylinder.

[0045] like Figures 1-3As shown, the PEEK gas cylinder was designed and modeled using modeling software to determine its dimensions, shape, and other parameters. The model was then imported into Cura slicing software for processing, yielding slicing parameter data for the PEEK gas cylinder model. This data facilitates the subsequent 3D printing process. The printing substrate was placed on the forming base plate and secured with a fixing device to support the PEEK gas cylinder. Before printing began, the gap between the printing nozzle and the printing sticker was adjusted. The Z-axis distance was set and, after reaching the negative limit, the leveling knob was rotated for coarse adjustment, adjusting the gap between the printing nozzle and the printing sticker to 0.1mm-0.2mm. Test printing was conducted, and fine-tuning was performed based on the printing results. The melt heating module and hopper temperatures were set, with the print nozzle temperature set to 420℃ and the filament and hopper heating temperatures set to 100℃. A temperature sensor in the melt extrusion module was connected to the control module. The temperature sensor measured the melt temperature in real time and transmitted the data to the control module. The control module used the system measurement results to control the heating module to adjust the melt temperature in real time, ensuring that the printed PEEK material always melted at a suitable temperature, avoiding excessive temperature that could cause polymer crosslinking or degradation. When the print nozzle temperature reached 420℃, a test print of the PEEK melt was performed, using the control module to control the PEEK melt flow. Before printing, observe whether the PEEK filaments emerge smoothly from the print head. If the PEEK filaments emerge smoothly, the formal printing process can begin. Import the slicing parameter data of the PEEK cylinder model into the control module and set the printing parameters as follows: Melt nozzle extrusion layer height is set to 0.2mm, line width to 0.4mm, initial layer height to 0.15mm, and initial layer line width to 100%; melt nozzle extrusion wall thickness is set to 1.2mm, wall line runs are set to 3, outer wall embedment is 0.2mm, outer wall first, then inner wall, with the gap between the inner and outer walls fully filled and Z-seam aligned; fill density is set to 100%, and fill line distance is 0.4mm. The filling pattern is a straight line, the filling line multiplier is 1, the filling overlap percentage is 10%, and the filling overlap is 0.04mm; the flow rate is set to 100%, the initial layer flow rate is 100%; the filling speed is set to 25mm / s, the outer wall speed is 25mm / s, the inner wall speed is 30mm / s, the idle speed is 80mm / s, and the initial layer speed is 22.5mm / s. The melt extrusion module and the forming module are controlled to print the PEEK cylinder. After printing, the fully printed molded body is removed from the forming base plate. Compared with the previous parameter settings, the filling speed is reduced in this invention, and the filling overlap percentage is adjusted from the original 5% to 10%, and the filling overlap is adjusted from the original 0.02mm to 0.By reducing the filler thickness to 0.04mm and increasing the filling ratio, cavitation was significantly reduced, leading to improved PEEK cylinder product quality. Post-printing processing of the PEEK cylinders involved polishing to remove pinpoint overflow marks from the molded surface, and annealing to eliminate any internal stress that may have been present during the manufacturing process, thereby increasing the strength and appearance quality of the finished PEEK cylinders.

[0046] Working Principle: In this invention, PEEK gas cylinders are 3D printed using FDM (Fused Deposition Modeling) technology. Experiments were conducted on two high-temperature fused deposition modeling (FDDM) machines to investigate the effects of different printing process parameters on the mechanical properties of the samples. The results showed that, under the same printing direction, the tensile strength, elongation at break, and notched impact strength of the sample printed at a higher printing speed were lower than those printed at a lower printing speed. At the same printing speed, the tensile strength, elongation at break, and notched impact strength of the FDM sample printed along the X and Y directions were higher than those printed along the Z direction, indicating that FDDM... The M-shaped body is more fragile in the Z-direction; a molding environment above room temperature is conducive to the fusion of melts, thereby improving the bonding strength of the molded body in the Z-direction; therefore, based on the above conclusions, this invention uses an FDM device with a high-temperature chamber environment to mold PEEK material, adjusting the printing parameters as follows: layer height set to 0.2mm, trace width set to 0.4mm, initial layer height set to 0.15mm, initial layer trace width set to 100%; wall thickness set to 1.2mm, wall trace count set to 3, outer wall embedding 0.2mm, outer wall first then inner wall, with the inner wall between the outer and inner walls... The voids were set to be fully filled, with Z-seam alignment; the fill density was set to 100%, the fill line distance to 0.4mm, the fill pattern to be straight lines, the fill line multiplier to 1, the fill overlap percentage to 10%, and the fill overlap to 0.04mm; the flow rate was set to 100%, and the initial layer flow rate to 100%; the fill speed was set to 25mm / s, the outer wall speed to 25mm / s, the inner wall speed to 30mm / s, the empty running speed to 80mm / s, and the initial layer speed to 22.5mm / s. PEEK material was printed using these parameters. The resulting PEEK cylinder was then polished. Grinding and annealing processes yield the finished PEEK gas cylinder, improving both its strength and appearance. During melt extrusion, the control system in the control module manages and adjusts the printing process in real time. A temperature sensor in the melt extrusion module measures the melt temperature in real time and transmits the data to the control module, which then controls the heating module to adjust the melt temperature accordingly. This ensures that the PEEK material melts at a suitable temperature, preventing excessive heat from causing polymer crosslinking or degradation, which would negatively impact the molding quality of the PEEK material.

[0047] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An optimized method for fabricating 3D-printed PEEK gas cylinders based on FDM technology, comprising a control module, a motion module, a feeding module, a melt extrusion module, and a forming module, characterized in that: The control module is connected to the motion module, feeding module, melt extrusion module and forming module respectively, and controls the operation of each module; The motion module is connected to the feeding module, the melt extrusion module, and the forming module, and drives the module to move. The set temperature of the molding space within the molding module is higher than the glass transition temperature of the PEEK material, which is 143°C. The parameters of the melt extrusion module are set as follows: The melt nozzle extrusion layer height is set to 0.2mm, the trace width is set to 0.4mm, the initial layer height is set to 0.15mm, and the initial layer trace width is set to 100%. The melt nozzle extrusion wall thickness is set to 1.2mm, the number of wall lines is set to 3, the outer wall is embedded 0.2mm, the outer wall is filled first and then the inner wall, the gap between the inner and outer walls is filled completely, and the Z-slits are aligned. The fill density is set to 100%, the fill trace distance is 0.4mm, the fill pattern is a straight line, the fill trace multiplier is 1, the fill overlap percentage is 10%, and the fill overlap is 0.04mm. The flow rate is set to 100%, and the initial layer flow rate is 100%. The filling speed is set to 25 mm / s, the outer wall speed is set to 25 mm / s, the inner wall speed is set to 30 mm / s, the empty running speed is set to 80 mm / s, and the initial layer speed is set to 22.5 mm / s.

2. The optimized method for fabricating 3D-printed PEEK gas cylinders based on FDM technology according to claim 1, characterized in that: The feeding module is equipped with a wire feeding wheel to continuously and quantitatively transport raw materials to the melt extrusion module.

3. An optimized method for fabricating 3D-printed PEEK gas cylinders based on FDM technology according to claim 1, characterized in that: The melt extrusion module includes a heating module, a throat, a melt nozzle, and a temperature sensor. The heating module is controlled by a control module. The heating module is connected to the throat, the throat is connected to the melt nozzle, and the temperature sensor is connected to the control module.

4. An optimized method for fabricating 3D-printed PEEK gas cylinders based on FDM technology according to claim 1, characterized in that: The molding module is equipped with a molding base plate, which supports the melt molding process.

5. An optimized method for fabricating 3D-printed PEEK gas cylinders based on FDM technology according to claim 1, characterized in that: The optimized method for fabricating 3D-printed PEEK gas cylinders using the FDM process is as follows: The gas cylinder was designed and modeled, and the model was processed using Cura slicing software to obtain slice data; Fix the printing substrate by placing it on the molding base plate and fixing it with a fixing device; Adjust the gap between the print nozzle and the sticker, set the Z-axis distance to the negative limit, then turn the leveling knob for coarse adjustment. Adjust the gap between the print nozzle and the sticker to between 0.1mm and 0.2mm, perform a test print, and make fine adjustments again based on the print results. Set the melt heating module and hopper temperature, and set the printing nozzle temperature to 420℃ and the wire and hopper heating temperature to 100℃. For the PEEK melt test print, once the print nozzle temperature reaches 420℃, click "feed" on the manual interface operation screen and observe whether the PEEK filament is flowing smoothly out of the print head. Proceed to the next step once the filament is flowing smoothly. Slice data selection and reading: Import the model's slice data into the device, enter the control program's printing page, select and read the corresponding file, and set the printing parameters: Once the parameters are confirmed to be correct, printing can begin. Remove the molded body. After printing is complete, remove the fully printed molded body from the molding base plate. Post-processing of gas cylinders involves polishing, grinding, and annealing the printed PEEK gas cylinder semi-finished products to obtain the finished PEEK gas cylinders.

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