A large-size, high-precision ceramic photopolymerization jet deposition composite additive manufacturing equipment

Abstract

This invention relates to the field of additive manufacturing of large-size, high-precision ceramic components, and more specifically, to a large-size, high-precision ceramic photopolymerization jet deposition composite additive manufacturing equipment and its process control flow. The equipment includes a high-precision three-coordinate displacement mechanism, a dynamic push-broom photopolymerization forming module, a real-time waste material cleaning module, a fiber jet toughening module, and a cavity resin filling module. The dynamic push-broom photopolymerization forming module, the real-time waste material cleaning module, the fiber jet toughening module, and the cavity resin filling module are all mounted on the high-precision three-coordinate displacement mechanism. The two-dimensional free push-broom method allows for arbitrary trajectory planning according to the characteristics of the formed component, reducing ineffective travel and significantly improving forming efficiency.

Description

Technical Field

[0001] This invention relates to the field of additive manufacturing of large-size, high-precision ceramic components, and more specifically to a large-size, high-precision ceramic photopolymerization jet deposition composite additive manufacturing equipment. Background Technology

[0002] Advanced complex ceramic components are a crucial foundation for supporting the development of my country's next-generation aviation, aerospace, and other strategic emerging industries. Additive manufacturing is a revolutionary technology for forming complex ceramic components. Large-size, complex-structured special ceramic key components in key fields such as aviation, aerospace, and energy and chemical industries have an urgent need for high-precision manufacturing equipment. However, existing ceramic additive manufacturing equipment suffers from common problems that fail to meet manufacturing demands. These common problems manifest in three main aspects: First, the forming platform has a heavy load capacity and the scraper has a large length-to-diameter ratio. Current mainstream large-size ceramic additive manufacturing equipment achieves Z-axis forming of components through a moving forming platform, resulting in a huge platform load. Simultaneously, conventional large-size equipment uses a scraper to flatten the entire surface, resulting in a large length-to-diameter ratio, low scraper rigidity, and easy deformation during the flattening process, making it impossible to guarantee accuracy. Second, large-format forming is costly and inefficient. Existing mainstream additive manufacturing equipment generally uses either fixed or moving light sources. The fixed light source solution requires a large number of light sources due to the large forming area, leading to high costs. The moving light source solution involves static single-format splicing, resulting in numerous splicing gaps, low forming quality, and low efficiency. While the efficiency and quality of one-dimensional dynamic brushing have improved, they are still insufficient for forming complex structures and paths. Thirdly, forming and toughening cavity structures are difficult. Due to the lack of a real-time cleaning module, cavity structures lack support and cannot be formed. Uncured ceramic paste inside the cavity structure cannot be removed, affecting accuracy. Conventional materials have low toughness, making it impossible to lay continuous fibers, resulting in poor toughening effects. This patent addresses these challenges by proposing a new multi-process composite additive manufacturing equipment with functions including accompanying scraper feeding, follow-up printing forming, and conformal two-dimensional brushing. Summary of the Invention

[0003] To overcome the shortcomings of existing technologies, this invention provides a large-size, high-precision ceramic photopolymerization jet deposition composite additive manufacturing equipment. Its advantages are that it adopts a two-dimensional free push-broom method, which can plan any trajectory according to the characteristics of the formed component, reduce ineffective strokes, and greatly improve forming efficiency.

[0004] A large-size, high-precision ceramic photocuring jet deposition composite additive manufacturing equipment includes a high-precision three-coordinate displacement mechanism, a dynamic push-broom photocuring forming module, a real-time waste material cleaning module, a fiber jet toughening module, and a cavity resin filling module. The dynamic push-broom photocuring forming module, the real-time waste material cleaning module, the fiber jet toughening module, and the cavity resin filling module are all mounted on the high-precision three-coordinate displacement mechanism.

[0005] The high-precision three-axis displacement mechanism includes a marble table, an X-axis displacement subsystem, a Y-axis displacement subsystem, and a Z-axis displacement subsystem;

[0006] An X-axis displacement subsystem is fixed on the marble platform, a Y-axis displacement subsystem is installed on the X-axis displacement subsystem, and a Z-axis displacement subsystem is installed on the Y-axis displacement subsystem.

[0007] The Z-axis displacement subsystem includes a left ball screw and a right ball screw;

[0008] The dynamic push-broom photocuring molding module is installed on the right ball screw, while the residual material real-time cleaning module, fiber spraying toughening module, and cavity resin filling module are installed on the left ball screw.

[0009] The dynamic push-broom photopolymerization molding module includes an optical engine, a web splicing mechanism, a scraper feeding mechanism, and a lifting mechanism.

[0010] The scraper feeding mechanism is installed on the lifting mechanism; the optical engine can project the set pattern and cure the smoothed ceramic paste; the image splicing mechanism can splice the projection images of multiple optical engines.

[0011] The residual material real-time cleaning module includes a high-pressure gas nozzle and a second lifting mechanism. The high-pressure gas nozzle is installed on the second lifting mechanism and is connected to an external air pump.

[0012] The fiber spray toughening module is used to introduce continuous fiber reinforcement through spray forming, thereby toughening the ceramic component.

[0013] The cavity resin filling module includes an FDM printhead and a lifting mechanism three. The FDM printhead is mounted on the lifting mechanism three and fills the cavity of the printed part with burnable resin support.

[0014] A printing process control flow for a large-size, high-precision ceramic photopolymer jet deposition composite additive manufacturing equipment includes the following steps:

[0015] Step 1: When printing begins, all modules are in their initial state; the XYZ axes return to zero, ready to begin printing the first layer; at this time, all process modules are above the working plane;

[0016] Step 2: Perform the dynamic push-broom photocuring process; Lifting mechanism 1 drives the scraper feeding mechanism to descend to the working plane; material begins to flow from the feeding port, and the high-precision three-coordinate displacement mechanism moves along the planned path on the XY axis. The scraper smooths the flowing ceramic paste, and the corresponding pattern projected by the photomechanical system cures the smoothed ceramic paste accordingly; After completion, single-layer printing has completed ceramic feeding, smoothing, and photocuring; Lifting mechanism 1 drives the scraper feeding mechanism to rise, and the XY axis returns to zero;

[0017] Step 3: Perform the real-time cleaning process for residual materials; Lifting mechanism 2 drives the high-pressure gas nozzle to descend and reach the working plane; The high-precision three-coordinate displacement mechanism moves along the planned path on the XY axis, and the high-pressure gas nozzle sprays out high-pressure gas to clean up the uncured ceramic paste; After cleaning is completed, lifting mechanism 2 rises and the XY axis returns to zero.

[0018] Step 4: Perform the fiber spraying toughening process; the high-precision three-coordinate displacement mechanism moves along the planned path along the XY axis, and the fiber spraying toughening module begins to spray continuous fibers coated with ceramic paste, laying and toughening them where needed;

[0019] Step 5: Perform the cavity resin filling process; the lifting mechanism 3 drives the resin print head to descend and reach the working plane; the three-axis displacement mechanism moves the XY axis to the cavity position according to the planned path, and the FDM print head prints burnable resin at the cavity to fill the entire cavity; after filling, the lifting mechanism 3 rises and the XY axis returns to zero.

[0020] Step 6: After single-layer printing is completed, the Z-axis rises by the thickness of one printing layer to prepare for the next layer printing and enter the initial state of the next layer printing; this cycle is repeated until the printed part is formed; after the overall printing is completed, the printed part is removed and degreased and sintered. The resin in the cavity is sintered away and the cavity is formed, and the printing is officially completed.

[0021] The beneficial effects of this invention, a large-size, high-precision ceramic photopolymerization jet deposition composite additive manufacturing equipment, are:

[0022] By controlling the lifting and lowering of each module, they can operate at different heights, thus avoiding interference and achieving coordinated control. Specifically, the scraper and photomechanical unit of the dynamic push-broom photocuring module move together, simultaneously performing material feeding, leveling, and curing functions, reducing switching time. The two-dimensional free push-broom method allows for arbitrary trajectory planning based on the characteristics of the formed component, reducing ineffective travel and significantly improving forming efficiency. Attached Figure Description

[0023] The present invention will now be described in further detail with reference to the accompanying drawings and specific implementation methods.

[0024] Figure 1 An overall diagram of a large-size, high-precision ceramic photopolymerization jet deposition composite additive manufacturing equipment;

[0025] Figure 2 Partial view of a large-size, high-precision ceramic photopolymerization jet deposition composite additive manufacturing equipment;

[0026] Figure 3 A schematic diagram of a dynamic push-broom photopolymerization molding module. Figure 1;

[0027] Figure 4 A schematic diagram of a dynamic push-broom photopolymerization molding module. Figure 2 ;

[0028] Figure 5 This is a schematic diagram of the integrated installation of the three-process modules;

[0029] Figure 6 Flowchart for preprocessing printed models;

[0030] Figure 7 This is a flowchart for the control process of a single-layer printing operation.

[0031] High-precision three-axis displacement mechanism 11; marble table 111; X-axis displacement subsystem 112; Y-axis displacement subsystem 113; Z-axis displacement subsystem 114; left ball screw 1141; right ball screw 1142;

[0032] 12. Dynamic push-broom photocuring molding module; 13. Real-time residual material cleaning module; 14. Fiber spray toughening module; 15. Cavity resin filling module;

[0033] Optical machine 21; Splicing mechanism 22; Scraper feeding mechanism 23; Feeding port 231; Scraper 232; Lifting mechanism 1 24;

[0034] 31. High-pressure gas nozzle; 32. Lifting mechanism II; 34. FDM printhead; 35. Lifting mechanism III. Detailed Implementation

[0035] like Figure 1-5 As shown, the present invention mainly proposes a large-size, high-precision ceramic photocuring jet deposition composite additive manufacturing equipment, including a high-precision three-coordinate displacement mechanism 11, a dynamic push-broom photocuring forming module 12, a residual material real-time cleaning module 13, a fiber jet toughening module 14, and a cavity resin filling module 15. The dynamic push-broom photocuring forming module 12, the residual material real-time cleaning module 13, the fiber jet toughening module 14, and the cavity resin filling module 15 are all mounted on the high-precision three-coordinate displacement mechanism 11.

[0036] The high-precision three-axis displacement mechanism 11 includes a marble table 111, an X-axis displacement subsystem 112, a Y-axis displacement subsystem 113, and a Z-axis displacement subsystem 114.

[0037] An X-axis displacement subsystem 112 is fixed on the marble platform 111, a Y-axis displacement subsystem 113 is installed on the X-axis displacement subsystem 112, and a Z-axis displacement subsystem 114 is installed on the Y-axis displacement subsystem 113.

[0038] The Z-axis displacement subsystem 114 includes a left ball screw 1141 and a right ball screw 1142;

[0039] The dynamic push-broom photocuring molding module 12 is mounted on the right-side ball screw 1142, while the residual material real-time cleaning module 13, the fiber spraying toughening module 14, and the cavity resin filling module 15 are mounted on the left-side ball screw 1141. The high-precision three-coordinate displacement mechanism 11 can drive the dynamic push-broom photocuring molding module 12, the residual material real-time cleaning module 13, the fiber spraying toughening module 14, and the cavity resin filling module 15 to achieve movement in the XYZ directions.

[0040] The dynamic push-broom photopolymerization molding module 12 includes an optical engine 21, a web splicing mechanism 22, a scraper feeding mechanism 23, and a lifting mechanism 24.

[0041] The scraper feeding mechanism 23 is installed on the lifting mechanism 24 and can realize the feeding and leveling functions of ceramic paste; the optical engine 21 can project the set pattern and cure the leveled ceramic paste; the image splicing mechanism 22 can realize the splicing of the projection images of multiple optical engines.

[0042] The dynamic push-broom photocuring molding module 12, driven by the high-precision three-coordinate displacement mechanism 11, realizes the functions of feeding, leveling and curing ceramic paste.

[0043] The residual material real-time cleaning module 13 includes a high-pressure gas nozzle 31 and a lifting mechanism 2 32. The high-pressure gas nozzle 31 is installed on the lifting mechanism 2 32. The high-pressure gas nozzle 31 is connected to an external air pump and can spray high-pressure gas to clean uncured ceramic paste.

[0044] The fiber spray toughening module 14 is used to introduce continuous fiber reinforcement through spray forming to toughen ceramic components.

[0045] The cavity resin filling module 15 includes an FDM printhead 34 and a lifting mechanism 35. The FDM printhead 34 can be a self-designed FDM resin printhead or an existing commercially available FDM resin printhead. The FDM printhead 34 is mounted on the lifting mechanism 35 and fills the cavity of the printed part with burnable resin support.

[0046] like Figure 5 As shown, before printing begins, the model preprocessing system slices the three-dimensional model of the printable part, plans the path that the high-precision three-coordinate displacement mechanism 11 needs to move when executing each process, and processes the sliced ​​images to obtain the pattern set of projection required by each optical engine.

[0047] After printing begins, the process flow chart for single-layer printing is as follows: Figure 6 As shown.

[0048] A printing process control flow for a large-size, high-precision ceramic photopolymer jet deposition composite additive manufacturing equipment mainly includes the following steps:

[0049] Step 1: When printing begins, all modules are in their initial state; the XYZ axes return to zero, ready to begin printing the first layer; at this time, all process modules are above the working plane;

[0050] Step 2: Perform the dynamic push-broom photocuring process; the lifting mechanism 24 drives the scraper feeding mechanism 23 to descend to the working plane; the feeding port begins to discharge material, the high-precision three-coordinate displacement mechanism 11 moves along the planned path, the scraper 232 scrapes the flowing ceramic paste, and the photomechanical system 21 projects the corresponding pattern to cure the scraped ceramic paste; after the process is completed, the single-layer printing has completed ceramic feeding, scraping and photocuring; the lifting mechanism 24 drives the scraper feeding mechanism 23 to rise, and the XY axis returns to zero;

[0051] Step 3: Perform the real-time cleaning process for residual materials; Lifting mechanism 2 32 drives the high-pressure gas nozzle 31 to descend to the working plane; the high-precision three-coordinate displacement mechanism 11 moves the XY axis according to the planned path, and the high-pressure gas nozzle 31 sprays high-pressure gas to clean up the uncured ceramic paste; after cleaning, lifting mechanism 2 32 rises and the XY axis returns to zero.

[0052] Step 4: Perform the fiber spraying toughening process; the high-precision three-coordinate displacement mechanism 11 moves along the planned path, and the fiber spraying toughening module 14 begins to spray continuous fibers coated with ceramic paste, laying and toughening them where needed;

[0053] Step 5: Perform the cavity resin filling process; Lifting mechanism 35 drives the resin print head to descend and reach the working plane; the three-coordinate displacement mechanism 11 moves the XY axis to the cavity position according to the planned path, and the FDM print head 34 prints burnable resin at the cavity to fill the entire cavity; after filling, lifting mechanism 35 rises and the XY axis returns to zero.

[0054] Step 6: After single-layer printing is completed, the Z-axis rises by the thickness of one printing layer to prepare for the next layer printing and enter the initial state of the next layer printing; this cycle is repeated until the printed part is formed; after the overall printing is completed, the printed part is removed and degreased and sintered. The resin in the cavity is sintered away and the cavity is formed, and the printing is officially completed.

Claims

1. A large-size, high-precision ceramic photopolymerization jet deposition composite additive manufacturing equipment, comprising a high-precision three-coordinate displacement mechanism (11), a dynamic push-broom photopolymerization forming module (12), a real-time residue cleaning module (13), a fiber jet toughening module (14), and a cavity resin filling module (15), characterized in that: The dynamic push-broom photocuring molding module (12), the residual material real-time cleaning module (13), the fiber spraying toughening module (14), and the cavity resin filling module (15) are all mounted on the high-precision three-coordinate displacement mechanism (11); The high-precision three-axis displacement mechanism (11) includes a marble table (111), an X-axis displacement subsystem (112), a Y-axis displacement subsystem (113), and a Z-axis displacement subsystem (114); An X-axis displacement subsystem (112) is fixed on the marble platform (111), a Y-axis displacement subsystem (113) is installed on the X-axis displacement subsystem (112), and a Z-axis displacement subsystem (114) is installed on the Y-axis displacement subsystem (113). The Z-axis displacement subsystem (114) includes a left ball screw (1141) and a right ball screw (1142); The dynamic push-broom photocuring molding module (12) is installed on the right ball screw (1142), and the residual material real-time cleaning module (13), fiber spray toughening module (14), and cavity resin filling module (15) are installed on the left ball screw (1141). The dynamic push-broom photopolymerization molding module (12) includes an optical engine (21), a web splicing mechanism (22), a scraper feeding mechanism (23), and a lifting mechanism (24); The scraper feeding mechanism (23) is installed on the lifting mechanism (24); the optical engine (21) can project the set pattern and cure the smoothed ceramic paste; the image splicing mechanism (22) can realize the splicing of the projection images of multiple optical engines; The cavity resin filling module (15) includes an FDM printhead (34) and a lifting mechanism (35). The FDM printhead (34) is mounted on the lifting mechanism (35) and fills the cavity of the printed part with burnable resin support.

2. The large-size, high-precision ceramic photopolymerization jet deposition composite additive manufacturing equipment according to claim 1, characterized in that: The residual material real-time cleaning module (13) includes a high-pressure gas nozzle (31) and a second lifting mechanism (32). The high-pressure gas nozzle (31) is installed on the second lifting mechanism (32) and is connected to an external air pump.

3. The large-size, high-precision ceramic photopolymerization jet deposition composite additive manufacturing equipment according to claim 1, characterized in that: The fiber spray toughening module (14) is used to introduce continuous fiber reinforcement through spray forming to toughen ceramic components.

4. The printing process control flow of a large-size, high-precision ceramic photopolymerization jet deposition composite additive manufacturing equipment according to claim 2, characterized in that, Includes the following steps: Step 1: When printing begins, all modules are in their initial state; The XYZ axes return to zero, ready to begin printing the first layer; at this time, all process modules are above the working plane; Step 2: Perform dynamic push-broom photocuring forming process; Lifting mechanism 1 (24) drives the scraper feeding mechanism (23) to descend and reach the working plane; the feeding port starts to discharge material, the high-precision three-coordinate displacement mechanism (11) moves along the planned path on the XY axis, the scraper (232) scrapes the flowing ceramic paste, and the optical engine (21) projects the corresponding pattern to cure the scraped ceramic paste; after the execution is completed, the single-layer printing has completed ceramic feeding, scraping and photocuring; Lifting mechanism 1 (24) drives the scraper feeding mechanism (23) to rise, and the XY axis returns to zero; Step 3: Perform the real-time cleaning process for residual materials; the lifting mechanism 2 (32) drives the high-pressure gas nozzle (31) to descend and reach the working plane; the high-precision three-coordinate displacement mechanism (11) moves along the planned path on the XY axis, and the high-pressure gas nozzle (31) sprays out high-pressure gas to clean up the uncured ceramic paste; after cleaning, the lifting mechanism 2 (32) rises and the XY axis returns to zero. Step 4: Perform the fiber spraying toughening process; the high-precision three-coordinate displacement mechanism (11) moves along the planned path on the XY axis, and the fiber spraying toughening module (14) begins to spray continuous fibers coated with ceramic paste, laying and toughening them where needed; Step 5: Perform the cavity resin filling process; the lifting mechanism three (35) drives the resin print head to descend and reach the working plane; the three-coordinate displacement mechanism (11) moves the XY axis to the cavity position according to the planned path, and the FDM print head (34) prints burnable resin at the cavity to fill the entire cavity; after filling, the lifting mechanism three (35) rises and the XY axis returns to zero. Step 6: After single-layer printing is completed, the Z-axis rises by the thickness of one printing layer to prepare for the next layer printing and enter the initial state of the next layer printing. This process is repeated until the printed part is formed; After the overall printing is completed, the printed part is removed and degreased and sintered. The resin in the cavity is sintered away and the cavity is formed, and the printing is officially completed.

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