A rotatable hot roller system and method for continuous fiber 3D printing

Abstract

A rotatable hot roller system and method for continuous fiber 3D printing, including a fiber tensioning device, the fiber tensioning device is fixed on a gantry printing table beam, the gantry printing table beam is connected to a force control feedback device, and the bottom of the force control feedback device is connected to a hot pressing device; the force control feedback device includes a screw guide rail, a first stepper motor is connected to the screw guide rail, and a slider is connected to the screw guide rail; the slider is connected to a hollow rotating platform and a tension sensor; a pressure sensor is connected between the bottom of the hollow rotating platform and the hot pressing device; a second stepper motor for driving the rotation of the hot pressing device is connected above the hollow rotating platform, the screw guide rail is connected to a heating block, the heating block is above the hot pressing device, and a printing nozzle is connected below the heating block; the present invention achieves precise matching of the hot pressing direction and the printing path through the rotatable hot roller, and achieves real-time adjustment of the hot roller pressure and the fiber tensioning force through the force control feedback device, thereby significantly improving the mechanical properties of the printed sample.

Description

Technical Field

[0001] The present invention belongs to the field of 3D printing technology, and in particular relates to a rotatable hot roller system and method for continuous fiber 3D printing. Background Art

[0002] To meet the manufacturing industry's need for rapid production of complex structures, 3D printing technology has garnered widespread attention in the industrial sector. However, the lack of durability of existing 3D printing materials in engineering applications, coupled with the limitations of 3D printing equipment hardware, has limited the application of this technology to prototyping. To expand 3D printing processes to the final product manufacturing stage, high-performance semi-crystalline polymers such as polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and polyphenylene sulfide (PPS) are becoming the materials of choice for high-performance 3D printing. These materials, with their excellent high-temperature stability and mechanical properties, are suitable for the manufacture of parts in extreme operating environments and offer good compatibility with existing 3D printing systems.

[0003] Currently, the main challenge of high-performance 3D printing technology lies in its low interlayer bonding strength. To improve the mechanical properties of printed parts, researchers have proposed several improvements, such as the patent application "A Ground-Based Experimental Device for Simulating Space Environment 3D Printing" (Publication No.: CN105716892A), which addresses 3D printing in a vacuum environment, and the patent application "A Semi-Open High-Temperature Rotary Printing Device and Process" (Publication No.: CN118163354A), which addresses high-temperature 3D printing. These methods improve the mechanical properties of printed parts by adjusting the processing environment. Furthermore, another patent application, "A Deformable Hot Pressing 3D Printing Device" (CN112873830A), introduces a hot roller mechanism to increase pressure during the printing process to improve the mechanical properties of printed parts. While these methods can improve the mechanical properties of 3D printed parts to a certain extent, they have limitations in their application scenarios and require high equipment requirements. Existing hot pressing devices use fixed hot rollers, which restrict the printing direction and path selection. Furthermore, they cannot dynamically adjust the pressure and fiber tension during the printing process, resulting in limited improvement in mechanical properties.

[0004] In summary, at present, there is a lack of a printing device that is suitable for a variety of occasions and has low cost, high efficiency and controllability to effectively improve the interlayer bonding performance of 3D printed samples. This technical bottleneck seriously restricts the widespread application of high-performance 3D printing technology in the industrial field, especially in the manufacturing of high-performance parts. Summary of the Invention

[0005] In order to overcome the shortcomings of the above-mentioned prior art, the purpose of the present invention is to provide a rotatable hot roller system and method for continuous fiber 3D printing, which realizes precise matching of the hot pressing direction and the printing path through the rotatable hot roller, and realizes real-time adjustment of the hot roller pressure and the fiber tensioning force through the force control feedback device, effectively reducing the defects that may occur during the printing process and significantly improving the mechanical properties of the printed samples.

[0006] In order to achieve the above object, the technical solution adopted by the present invention is:

[0007] A rotatable hot roller system for continuous fiber 3D printing includes a fiber tensioning device 1, which is fixed on a gantry printing platform beam 2. The gantry printing platform beam 2 is connected to a force control feedback device 4 through a connector 3, and a hot pressing device 5 is connected to the bottom of the force control feedback device 4.

[0008] The fiber tensioning device 1 includes a fixed cylinder 12 , both ends of which are supported on a left fiber support 13 and a right fiber support 14 , and one end of the fixed cylinder 12 is connected to a magnetic damper 15 ; the fixed cylinder 12 is sleeved with a continuous carbon fiber 11 .

[0009] The force control feedback device 4 includes a screw guide rail 42 connected to the connecting member 3, a first stepper motor 41 is connected to the screw guide rail 42, and a slider 44 is connected to the screw guide rail 42. The first stepper motor 41 is used to drive the slider 44 to perform linear motion; the slider 44 is connected to the hollow rotating platform 410 through a first special-shaped sheet metal part 45, and the first special-shaped sheet metal part 45 is connected to the tension sensor 47 through an L-shaped sheet metal part 46; a first pressure sensor 48 and a second pressure sensor 49 are connected between the bottom of the hollow rotating platform 410 and the hot pressing device 5; a second stepper motor 411 is connected above the hollow rotating platform 410, and the second stepper motor 411 drives the rotation of the hot pressing device 5; the screw guide rail 42 is connected to the heating block 413 through the second special-shaped sheet metal part 43, and the heating block 413 and the hollow rotating platform 410 are located on the same axis, and a printing nozzle 412 is connected above the hot pressing device 5 and below the heating block 413.

[0010] The hot pressing device 5 includes a connecting plate 51 , a U-shaped sheet metal part 52 is connected to the bottom of the connecting plate 51 , and the U-shaped sheet metal part 52 is connected to a hot rolling roller 53 via a heating rod.

[0011] The hot rolling roller 53 is provided with grooves to fix the position of the fibers when the fibers are turned.

[0012] A method of utilizing a rotatable heated roller system for continuous fiber 3D printing comprises the following steps:

[0013] 1) Generate a printing path for printing complex structures and set the corresponding pulse value of the second stepper motor 411 so that it drives the hot pressing device 5 to rotate through the hollow rotating platform 410 when the printing direction changes, achieving effective hot pressing in any printing direction;

[0014] 2) The first stepper motor 41 drives the slider 44 down to a certain height, and the initial pressure is monitored by the first pressure sensor 48 and the second pressure sensor 49;

[0015] 3) adjusting the damping force of the magnetic damper 15 so that the continuous fiber 11 is tensioned under the constraint of the compaction between the magnetic damper 15 and the hot roller 53, and monitoring the current tension through the tension sensor 47;

[0016] 4) Setting the temperature of the hot roller 53 and the heating block 413 according to the printing requirements;

[0017] 5) Real-time monitoring of printing pressure and fiber tension during the printing process, enabling multi-sensor real-time feedback and closed-loop control based on deep learning;

[0018] 6) Repeat steps 1) to 5) to print the next part.

[0019] The real-time monitoring in step 5) refers to establishing multi-sensor real-time feedback and closed-loop control based on deep learning, establishing the relationship between printing pressure, fiber tension and interlayer shear strength, and finding the optimal mechanical combination.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] Since the rotatable hot rolling roller of the present invention adopts a force-controlled feedback device, through real-time monitoring and closed-loop control by multiple sensors, it can dynamically adjust the hot pressing direction and pressure during the printing process to ensure precise control of fiber tension. Therefore, it has the advantages of effectively reducing microscopic pores and improving the surface quality and mechanical properties of printed parts. At the same time, the flexibility and manufacturing accuracy of the printing process are greatly improved, which reduces the overall manufacturing cost and provides a new solution for the promotion of high-performance 3D printing in industrial applications. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of the overall structure of the system according to an embodiment of the present invention.

[0023] Figure 2 Schematic diagram of a fiber tensioning device according to an embodiment of the present invention.

[0024] Figure 3 Schematic diagram of a force control feedback device according to an embodiment of the present invention.

[0025] Figure 4 Schematic diagram of a hot pressing device according to an embodiment of the present invention. DETAILED DESCRIPTION

[0026] The present invention is described in detail below with reference to the embodiments and accompanying drawings.

[0027] Reference Figure 1 A rotatable hot roller system for continuous fiber 3D printing includes a fiber tensioning device 1, which is fixed on a gantry printing platform beam 2. The gantry printing platform beam 2 is connected to a force control feedback device 4 through a connector 3. A hot pressing device 5 is connected to the bottom of the force control feedback device 4. This embodiment has good adaptability and can be quickly installed on different 3D printers, broadening the scope of application.

[0028] Reference Figure 2 The fiber tensioning device 1 includes a fixed cylinder 12, both ends of which are supported on a left fiber support 13 and a right fiber support 14, and one end of the fixed cylinder 12 is connected to a magnetic damper 15; the fixed cylinder 12 is covered with a continuous carbon fiber 11;

[0029] In this embodiment, the magnetic damper 15 is placed on one side of the right fiber support 14 . The tension range of the magnetic damper 15 is 20g-300g, and the torque range is 0.002n*m-0.02n*m.

[0030] Reference Figure 3 The force control feedback device 4 includes a screw guide rail 42 connected to the connecting member 3, a first stepper motor 41 is connected to the screw guide rail 42, and a slider 44 is connected to the screw guide rail 42, and the first stepper motor 41 is used to drive the slider 44 to move linearly; the slider 44 is connected to the hollow rotating platform 410 through a first special-shaped sheet metal part 45, and the first special-shaped sheet metal part 45 is connected to the tension sensor 47 through an L-shaped sheet metal part 46; a first pressure sensor 48 and a second pressure sensor 49 are connected between the bottom of the hollow rotating platform 410 and the hot pressing device 5; a second stepper motor 411 is connected above the hollow rotating platform 410, and the second stepper motor 411 drives the rotation of the hot pressing device 5; the screw guide rail 42 is connected to the heating block 413 through the second special-shaped sheet metal part 43, and the heating block 413 and the hollow rotating platform 410 are located on the same axis, and a printing nozzle 412 is connected above the hot pressing device 5 and below the heating block 413.

[0031] Reference Figure 4 The hot pressing device 5 includes a connecting plate 51, and a U-shaped sheet metal part 52 is connected to the bottom of the connecting plate 51. The U-shaped sheet metal part 52 is provided with holes for installing temperature sensors and heating rods; the U-shaped sheet metal part 52 is connected to the hot rolling roller 53 through the heating rod, and the hot rolling roller 53 is provided with grooves to fix the position of the fiber when the fiber is turned, thereby ensuring its follow-up performance.

[0032] In this embodiment, the continuous fiber 11 and the thermoplastic material are melt-impregnated in the heating block 413; the melted material is drawn out through the printing nozzle 412 and wound around the tension sensor 47 to monitor the current tension; then, the composite material filament passes through the hollow rotating platform 410 and is embedded in the groove of the hot rolling roller 53. Under the heating action of the hot rolling roller 53, the material is melted again and the printing is completed under the pressure of the hot rolling roller 53. The first pressure sensor 48 and the second pressure sensor 49 can monitor the current printing pressure in real time.

[0033] A method of utilizing a rotatable heated roller system for continuous fiber 3D printing comprises the following steps:

[0034] 1) Generate a printing path for printing complex structures and set the corresponding pulse value of the second stepper motor 411 so that it drives the hot pressing device 5 to rotate through the hollow rotating platform 410 when the printing direction changes, achieving effective hot pressing in any printing direction;

[0035] 2) The first stepper motor 41 drives the slider 44 down to a certain height, and the first pressure sensor 48 and the second pressure sensor 49 monitor whether the initial pressure is appropriate;

[0036] 3) Adjusting the damping force of the magnetic damper 15 so that the continuous fiber 11 is tensioned under the constraint of the compaction between the magnetic damper 15 and the hot roller 53, and monitoring whether the current tension is appropriate through the tension sensor 47;

[0037] 4) Setting the temperature of the hot roller 53 and the heating block 413 according to the printing requirements;

[0038] 5) Real-time monitoring of printing pressure and fiber tension during the printing process, enabling multi-sensor real-time feedback and closed-loop control based on deep learning;

[0039] 6) Repeat steps 1) to 5) to print the next part.

[0040] The real-time monitoring in step 5) refers to establishing multi-sensor real-time feedback and closed-loop control based on deep learning, establishing the relationship between printing pressure, fiber tension and interlayer shear strength, and finding the optimal mechanical combination.

[0041] In this embodiment, the printing path is first generated and the corresponding parameters of the second stepper motor 411 are set, so that the hot pressing device 5 can effectively rotate in any printing direction; secondly, the initial pressure and fiber tension are monitored and adjusted by adjusting the slider 44 and the magnetic damper 15; then, the temperature of the hot roller 53 and the heating block 413 is set, the printing pressure and fiber tension are monitored in real time, and deep learning is used to achieve real-time feedback and closed-loop control. The above steps are repeated to print multiple parts. Compared with the existing technology, the present invention uses multi-sensor real-time monitoring to achieve flexible adjustment of hot pressing direction, fiber tension and printing pressure, effectively reducing the microscopic pores of the sample, improving the surface quality and mechanical properties, enhancing the flexibility and reliability of manufacturing, and reducing manufacturing costs, providing a new approach for rapid manufacturing of high-performance 3D printing.

Claims

1. A method of utilizing a rotatable heated roller system for continuous fiber 3D printing, characterized in that: A rotatable hot roller system for continuous fiber 3D printing comprises a fiber tensioning device (1), the fiber tensioning device (1) being fixed on a gantry printing platform crossbeam (2), the gantry printing platform crossbeam (2) being connected to a force control feedback device (4) via a connector (3), and a hot pressing device (5) being connected to the bottom of the force control feedback device (4); The method comprises the following steps: 1) generating a printing path for printing a complex structure and setting a corresponding pulse value of a second stepper motor (411) so that when the printing direction changes, the hollow rotating platform (410) drives the hot pressing device (5) to rotate, thereby achieving effective hot pressing in any printing direction; 2) The first stepper motor (41) drives the slider (44) to descend to a certain height, and the initial pressure is monitored by the first pressure sensor (48) and the second pressure sensor (49); 3) adjusting the damping size of the magnetic damper (15) so that the continuous fiber (11) is tensioned under the constraint of the magnetic damper (15) and the hot roller (53), and monitoring the current tension through the tension sensor (47); 4) Setting the temperature of the hot roller (53) and the heating block (413) according to the printing requirements; 5) Real-time monitoring of printing pressure and fiber tension during the printing process, enabling multi-sensor real-time feedback and closed-loop control based on deep learning; 6) Repeat steps 1) to 5) to print the next part.

2. The method according to claim 1, wherein: The fiber tensioning device (1) comprises a fixed cylinder (12), the two ends of which are supported on a left fiber support (13) and a right fiber support (14), and one end of the fixed cylinder (12) is connected to a magnetic damper (15); and the fixed cylinder (12) is covered with a continuous carbon fiber (11).

3. The method according to claim 1, wherein: The force control feedback device (4) includes a screw guide rail (42) connected to the connecting member (3), a first stepper motor (41) is connected to the screw guide rail (42), a slider (44) is connected to the screw guide rail (42), and the first stepper motor (41) is used to drive the slider (44) to perform linear motion; the slider (44) is connected to the hollow rotating platform (410) through a first special-shaped sheet metal part (45), and the first special-shaped sheet metal part (45) is connected to the tension sensor (47) through an L-shaped sheet metal part (46); the bottom of the hollow rotating platform (410) and the thermal A first pressure sensor (48) and a second pressure sensor (49) are connected between the hot pressing device (5); a second stepper motor (411) is connected above the hollow rotating platform (410), and the second stepper motor (411) drives the rotation of the hot pressing device (5); the lead screw guide rail (42) is connected to the heating block (413) through the second special-shaped sheet metal part (43), and the heating block (413) and the hollow rotating platform (410) are located on the same axis, and a printing nozzle (412) is connected above the hot pressing device (5) and below the heating block (413).

4. The method according to claim 1, wherein: The hot pressing device (5) comprises a connecting plate (51), a U-shaped sheet metal part (52) is connected below the connecting plate (51), and the U-shaped sheet metal part (52) is connected to a hot rolling roller (53) via a heating rod.

5. The method according to claim 4, characterized in that: The hot rolling roller (53) is provided with a groove so as to fix the position of the fiber when the fiber is turned.

6. The method according to claim 1, wherein: The real-time monitoring in step 5) refers to establishing multi-sensor real-time feedback and closed-loop control based on deep learning, establishing the relationship between printing pressure, fiber tension and interlayer shear strength, and finding the optimal mechanical combination.

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