Oral disposable scanning rod 3D printing method

Abstract

The application discloses a kind of oral disposable scanning rod 3D printing methods, comprising: S1, phase setting structure monitoring interval layer and fusing layer thickness monitoring interval layer, generate monitoring interval layer with label;S2, judge layer thickness consistency by single layer, interlayer and the thickness detection of different positions in the same layer, realize repairability judgment and processing in combination with thickness deviation degree and root cause analysis;S3, joint optical imaging and ultrasonic detection surface crack and internal bubble evaluate structure integrity, dynamically adjust monitoring frequency;S4, based on demolition force, residual size and residual position evaluate support residual risk level and handle by grade.The application solves the problems of low monitoring efficiency and incomplete defect detection in the prior art through dynamic monitoring, multi-dimensional defect analysis and self-adaptive adjustment, significantly improves the printing qualification rate and production efficiency, and is suitable for batch manufacturing of high-precision oral scanning rods.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of 3D printing, and relates to a 3D printing method for a one-time oral scanning rod. BACKGROUND

[0002] With the development of digital dentistry technology, 3D printing is increasingly widely used in the manufacturing of personalized medical devices such as oral scanning rods. As a key component connecting the oral implant and the scanner, the accuracy and structural integrity of the scanning rod directly affect the effect of implant restoration. The traditional manufacturing method has problems such as low efficiency and poor consistency, while the existing 3D printing technology can realize rapid prototyping, but still has some shortcomings in the actual printing process, resulting in low product qualification rate and serious material waste.

[0003] (1) Single monitoring frequency: Existing technologies, such as the Chinese patent with publication number CN120307644A, disclose a method for generating a dental model, a dental model printing method and equipment, which mostly use fixed interval monitoring throughout the process. This method cannot dynamically adjust the monitoring density according to the risk differences in different stages of printing, resulting in missed detection in high-risk areas or excessive monitoring in low-risk areas.

[0004] (2) One-sided defect analysis: Existing technologies, such as the Chinese patent with publication number CN119217740A, disclose a method for making a fixed expansion arch appliance, which usually only detects a single indicator and lacks multi-dimensional joint analysis of layer thickness, structure, and support residue, making it difficult to comprehensively evaluate the printing quality.

[0005] (3) Lack of repair mechanism: Existing technologies directly terminate printing when deviations occur during the printing process, lacking judgment of repairability and adaptive adjustment strategies, resulting in the waste of salvageable printed parts and low production efficiency.

[0006] (4) Ignoring the risk of support residue: Existing technologies do not perform hierarchical evaluation on the size and position of support residue after removal and its functional impact, which may cause hidden dangers in subsequent clinical use. SUMMARY

[0007] To solve the above problems, the present application provides a 3D printing method for a one-time oral scanning rod, and the specific technical solution is as follows: a 3D printing method for a one-time oral scanning rod, comprising the following steps:

[0008] S1, monitoring interval layer setting: setting a structure monitoring interval layer according to the printing process and structural characteristics of the scanning rod, and setting a layer thickness monitoring interval layer based on the structure monitoring interval layer, and generating each monitoring interval layer of the printing and assigning a label, the label including layer thickness measurement, structure measurement and double measurement.

[0009] S2, layer thickness consistency detection: the intermediate printed part is detected for thickness of single layer, interlayer and same layer different positions, if the detection is qualified, the printing is continued, if not, whether it can be repaired is judged according to the thickness deviation degree and root cause, if it can be repaired, the printing is continued after repairing, if it cannot be repaired, the printing is terminated and stored in the overproof printed part library.

[0010] S3, structure integrity detection: surface crack information and internal bubble information of the intermediate printed part are acquired, whether the structure is complete is judged, if the structure is complete, the printing is continued and the setting of the structure monitoring interval layer is adaptively adjusted according to the detection result, if the structure is not complete, the printing is terminated and stored in the defect printed part library.

[0011] S4, support removal detection: after printing is completed, the removal force, residual size and residual position when the support is removed are measured, the risk level of the influence of support residue on the function of the scanning rod is evaluated and classified processing is carried out.

[0012] Compared with the prior art, the oral one-time scanning rod 3D printing method has the following beneficial effects:

[0013] 1. Dynamic optimization monitoring frequency: the present application balances the detection efficiency and defect detection rate by setting structure monitoring interval layers in stages and densely monitoring key parts, and reduces the equipment load.

[0014] 2. Multi-dimensional joint detection: the present application covers the quality hidden danger of the whole printing process by analyzing the layer thickness consistency, structure integrity and support residue risk.

[0015] 3. Intelligent repair and fault tolerance: the present application introduces thickness deviation degree and root cause analysis and repairability judgment mechanism, avoids printing termination caused by non-fatal errors, reduces material waste and improves production efficiency.

[0016] 4. Adaptive adjustment strategy: the present application dynamically reduces the monitoring interval according to the real-time detection result of the structure integrity, realizes the optimal balance of quality control and printing efficiency.

[0017] 5. Graded risk assessment: the present application comprehensively determines the support residue risk level by removal force, residual size and residual position, guides differentiated processing and improves product usability. BRIEF DESCRIPTION OF DRAWINGS

[0018] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following will briefly introduce the drawings needed to be used for the embodiment description. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without creative labor.

[0019] Figure 1A schematic diagram of the method flow of the present application.

[0020] Figure 2 A workflow diagram of the layer thickness consistency detection of the present application.

[0021] Figure 3 A workflow diagram of the structural integrity detection of the present application. DETAILED DESCRIPTION

[0022] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0023] Please refer to Figure 1 As shown in the figure, the present application provides a kind of oral disposable scanning rod 3D printing method, comprising the following steps:

[0024] S1, monitoring interval layer setting: according to the printing process and structural characteristics of scanning rod, structure monitoring interval layer is set, and layer thickness monitoring interval layer is set based on the structure monitoring interval layer, and the monitoring interval layer of printing is summarized and given label, the label includes measure layer thickness, measure structure and double measure.

[0025] As a preferred scheme, the specific analysis process of step S1 is:

[0026] S1.1, according to the printing process of scanning rod, determine the initial stage.

[0027] S1.2, based on the structural characteristics of scanning rod, identify key positions, the key positions include the positions of key structures and structure connection positions, the printing stage corresponding to the key positions is recorded as the key stage, and the printing stage corresponding to the non-key positions is recorded as the conventional stage.

[0028] S1.3, according to the preset rule, the number of structure monitoring interval layers in initial stage, key stage and conventional stage is set.

[0029] S1.4, obtain the historical value of the number of layer thickness monitoring interval layers.

[0030] S1.5, compare the number of structure monitoring interval layers in each stage with the historical value, and calculate the value closeness.

[0031] S1.6, based on the value closeness and the cumulative number of structure monitoring interval layers, the referenceability of structure monitoring interval layers in each stage to layer thickness monitoring interval layer setting is evaluated by weighted fusion.

[0032] S1.7, fix the structure monitoring interval layer number of the maximum referenceability stage as the layer thickness monitoring interval layer number.

[0033] S1.8, aggregate the structure monitoring interval layer and the layer thickness monitoring interval layer, generate each monitoring interval layer in the printing process and assign a label to each monitoring interval layer, the label including the layer thickness measurement, the structure measurement and the double measurement.

[0034] It should be noted that in 3D printing, the layer number refers to the total number of layers of material accumulation in the printing process. The core principle of 3D printing is to cut a three-dimensional model into countless thin layers along the height direction, and the printer melts or solidifies the material layer by layer, and finally stacks into a complete entity.

[0035] It should be noted that continuous real-time layer-by-layer monitoring of the scanning rod printing process will significantly increase the printing time and equipment load, and in actual application, not all working conditions require such a high monitoring frequency. Therefore, the present application adopts a periodic monitoring strategy to achieve optimization by setting a reasonable monitoring interval layer number.

[0036] It should be noted that the structure monitoring interval layer number refers to how many layers apart to perform a structure integrity monitoring. The layer thickness monitoring interval layer number refers to how many layers apart to perform a layer thickness consistency monitoring. In a specific embodiment, the layer thickness monitoring interval layer number is 10, i.e. layer thickness consistency is monitored every 10 layers, and the layer thickness monitoring interval layers are the 10th layer, the 20th layer, the 30th layer, etc.

[0037] It should be noted that the key structure location refers to stress concentration areas, etc., and the structure joint location refers to transition areas of different geometric shapes, etc. The key location is obtained by locating the scanning rod failure prone area through historical printing data or finite element analysis, and then the structure monitoring interval layer is set accordingly.

[0038] It should be noted that the preset rule refers to setting the structure monitoring interval layer number corresponding to the initial stage, key stage and regular stage according to historical printing data or experience.

[0039] It should be noted that the defect risk of the initial stage, key stage and regular stage is significantly different, and the monitoring frequency needs to be dynamically adjusted. The initial stage is the basis of printing quality, and its monitoring is to exclude the cumulative effect of early errors on subsequent printing. The key stage requires higher monitoring density to capture subtle defects, and the regular stage can appropriately reduce the frequency to improve efficiency.

[0040] It should be noted that the historical value of the layer thickness monitoring interval layer number is obtained through historical printing data.

[0041] It should be noted that the specific method for calculating the numerical closeness is: comparing the number of structure monitoring interval layers in each stage with the historical numerical value of the number of layer thickness monitoring interval layers to obtain a difference value, and based on a preset mapping relationship between the difference value and the numerical closeness, the numerical closeness is obtained. The smaller the difference value is, the greater the numerical closeness is.

[0042] It should be noted that when setting the layer thickness monitoring interval layer, it needs to be optimized based on the structure monitoring interval layer: first, by aligning the layer thickness monitoring interval layer with the structure monitoring interval layer, the synchronization of the monitoring process is realized, the number and time of printer pauses are reduced, and thus the production efficiency is improved; second, the set value of the layer thickness monitoring interval layer is ensured to be close to the historical data or experience value, so as to reduce the parameter deviation and ensure the scientificity and rationality of the monitoring scheme. Therefore, when evaluating the referenceability of the structure monitoring interval layer in each stage to the layer thickness monitoring interval layer, the higher the numerical closeness is, the more the cumulative number of structure monitoring interval layers is, and the higher the referenceability is.

[0043] It should be noted that the structure monitoring interval layer is set in a staged manner, which can avoid full-range high-frequency monitoring, reduce calculation and hardware load, and at the same time, densely monitor in the high-risk stage to improve the detection rate.

[0044] It should be noted that the layer thickness monitoring interval layer is set in a fixed manner, which can simplify the control logic, reduce the calculation complexity of real-time adjustment, and at the same time, the historical data under the same interval is easier to compare and analyze, and excessive monitoring is avoided. Moreover, the layer thickness consistency is more affected by the mechanical stability of the equipment and has lower relevance to the structural characteristics, and the fixed interval can ensure the detection coverage uniformity and avoid missing detection.

[0045] It should be noted that since the structure defect and the layer thickness deviation are often causally related and need to be analyzed jointly, and the structure monitoring interval layer in the key stage may have covered the high-occurrence area of layer thickness abnormalities, repeated detection produces redundancy, so the layer thickness monitoring interval layer is set on the basis of the structure monitoring interval layer. The coordination and fusion of the structure monitoring interval layer and the layer thickness monitoring interval layer can optimize the distribution of monitoring points, avoid resource waste, reduce redundant detection, and balance quality and speed.

[0046] It should be noted that the layer thickness monitoring tag indicates that the printing is paused when printing to this layer, and the layer thickness consistency monitoring is performed; the structure monitoring tag indicates that the printing is paused when printing to this layer, and the structure integrity monitoring is performed; and the double monitoring tag indicates that the printing is paused when printing to this layer, and the layer thickness consistency and structure integrity monitoring are simultaneously performed.

[0047] In this embodiment, the structure monitoring interval layer is set in stages, and densely monitored in key positions, so as to balance the detection efficiency and defect detection rate, and reduce the load of the equipment.

[0048] S2, layer thickness consistency detection: the intermediate printed part is detected for single layer, interlayer and same layer different position thickness, if the detection is qualified, the printing is continued, if not, whether it can be repaired is judged according to the thickness deviation degree and root cause, if it can be repaired, the printing is continued after repair, if it cannot be repaired, the printing is terminated and stored in the out-of-tolerance printed part library.

[0049] As a preferred solution, referring to Figure 2 The specific analysis process of step S2 is shown as follows:

[0050] S2.1, pause when the printer completes the printing of the current layer thickness monitoring interval layer.

[0051] S2.2, a plurality of measuring points are uniformly arranged on the current layer thickness monitoring interval layer according to the preset rule.

[0052] S2.3, the distance from each measuring point to the surface of the printing platform is measured by the probe, and the total theoretical thickness of the printed layer is subtracted to obtain the measured layer thickness of each measuring point and calculate the actual average layer thickness of the current layer thickness monitoring interval layer.

[0053] S2.4, compare the actual average layer thickness of the current layer thickness detection interval layer with the theoretical layer thickness to obtain the single layer thickness deviation.

[0054] S2.5, compare the measured layer thickness of each measuring point, and record the maximum difference as the thickness deviation of the same layer different position.

[0055] S2.6, compare the actual average layer thickness of the current layer thickness monitoring interval layer with the actual average layer thickness of the adjacent last layer thickness monitoring interval layer to obtain the interlayer thickness deviation.

[0056] S2.7, if the single layer, interlayer and same layer different position thickness deviation are all within the set allowable range, the layer thickness consistency detection is qualified and the printing is continued, otherwise the detection is unqualified and S2.8 is executed.

[0057] S2.8, evaluate the thickness deviation degree of the current layer thickness monitoring interval layer and analyze the root cause.

[0058] If the deviation degree is less than the set threshold and the root cause is the scraper system, it is determined that it can be repaired, and the printing is continued after repair.

[0059] Otherwise, it is determined that it cannot be repaired, the printing is terminated, the current layer thickness monitoring interval layer is marked as an out-of-tolerance layer and stored in the out-of-tolerance printed part library.

[0060] It should be noted that the intermediate printed part refers to the model which is not completely formed and still in the state of layer-by-layer accumulation during the printing process.

[0061] It should be noted that the measuring point arrangement mode of each layer thickness monitoring interval layer is the same.

[0062] It should be noted that, in order to avoid the influence of local protrusions or depressions on judgment, data needs to be collected at multiple uniformly distributed points of the layer thickness monitoring interval layer, and the average value is taken as the actual layer thickness of the layer.

[0063] It should be noted that, in addition to contact, the actual thickness can also be measured by non-contact. For example, by laser displacement sensor or camera to shoot the surface of the current layer thickness monitoring interval layer and compare with the reference surface of the printing platform to calculate the actual layer thickness.

[0064] It should be noted that, in a simulated analysis process, if the theoretical layer thickness is 0.1 mm, the current layer thickness monitoring interval layer is the 10th layer, the distance from the printing platform surface to the current layer thickness monitoring interval layer is 1.003 mm, and the total theoretical thickness of the previous 9 layers is 0.9 mm, the actual thickness of the 10th layer is 0.103 mm.

[0065] It should be noted that, in a simulated analysis process, if the layer thickness monitoring interval layer is the 10th layer, the 20th layer, the 30th layer, etc., and the current layer thickness monitoring interval layer is the 20th layer, the actual layer thickness of the current layer thickness monitoring interval layer is compared with the actual layer thickness of the 10th layer to obtain the interlayer thickness deviation.

[0066] It should be noted that the interlayer thickness deviation of the first layer thickness monitoring interval layer is a set value.

[0067] It should be noted that the single layer thickness deviation reflects the overall printing accuracy of the current layer, the interlayer thickness deviation reveals the Z-axis mechanical error or material shrinkage problem, and the same layer different position deviation detects the platform levelness or local material flow unevenness. From the three dimensions of single layer, interlayer and same layer different position, the thickness consistency can be detected comprehensively to cover the defect types and improve the detection accuracy and reliability.

[0068] It should be noted that when the layer thickness consistency detection is unqualified, a repairable or not judgment mechanism is added. If the deviation is slight and repairable, local repair is used to avoid overall scrap, reduce material waste and production cost; at the same time, it avoids directly terminating printing due to non-fatal errors, reduces idle time of equipment, and improves production efficiency; moreover, combined with real-time detection and repair mechanism, the printing process has fault tolerance capability.

[0069] It should be noted that if the layer thickness deviation is too large, even if the scraper is adjusted, the previously printed defective layer will become a hidden danger, and the subsequent layers may further amplify the deviation due to the unevenness of the bottom layer, and finally the finished product may not be used due to insufficient structural strength or size inconsistency. At this time, the printed part is recommended to be discarded.

[0070] It should be noted that if the layer thickness inconsistency is caused by non-scraper system, adjusting the scraper alone cannot solve the problem, and forcibly continuing printing will only cause the defect to expand, at which time the machine needs to be stopped to investigate other causes, and the printed part is discarded.

[0071] It should be noted that the specific position and deviation data of the recording out-of-tolerance layer are recorded to facilitate the statistical analysis of high-frequency defect patterns, which is beneficial to quality tracing and analysis and process improvement.

[0072] It should be noted that layer thickness consistency is a core indicator to ensure printing accuracy, and layer thickness deviation will cause model size error, poor layer adhesion, and even collapse.

[0073] In the present embodiment, the thickness deviation degree and root cause analysis and repairability judgment mechanism are introduced to avoid non-fatal error leading to printing termination, reduce material waste, and improve production efficiency.

[0074] As a preferred solution, the specific method for evaluating the thickness deviation degree in step S2.8 is:

[0075] The single-layer thickness deviation, interlayer thickness deviation, and same-layer different position thickness deviation of the current layer thickness monitoring interval layer are compared with the corresponding allowed range, and the amount of each deviation exceeding the allowed range is calculated, which is denoted as the thickness deviation excess.

[0076] According to the thickness deviation excess of the single layer, interlayer, and same-layer different position, and in combination with the preset weight of each deviation, the thickness deviation degree of the current layer thickness monitoring interval layer is calculated by weighted fusion.

[0077] It should be noted that the weights of single-layer, interlayer, and same-layer different position thickness deviation can be initially assigned through industry experience, or based on historical printing data statistical analysis of the correlation between different deviation types and component quality defects, regression analysis is used to calculate the contribution of each deviation to the structure performance, and after normalization, the weight value is converted, and the sum is 1.

[0078] As a preferred solution, the method for analyzing the root cause of the thickness deviation in step S2.8 is:

[0079] The scraper system of the printer is adjusted, and the next layer of the current layer thickness monitoring interval layer is continued to be printed as a subsequent layer.

[0080] After printing, the single-layer, interlayer, and same-layer different position thickness deviation of the subsequent layer is measured and compared with the corresponding deviation of the current layer thickness monitoring interval layer, and the thickness deviation adjustment amount is calculated.

[0081] According to the thickness deviation adjustment amount, in combination with the quantitative mapping relationship between the thickness deviation adjustment amount and the adjustment effect, the adjustment effect of the scraper system is evaluated.

[0082] If the adjustment effect reaches the preset expected value, the adjustment is effective, and it is determined that the thickness deviation of the current layer thickness monitoring interval layer is caused by the scraper system.

[0083] Otherwise, the adjustment is ineffective, and it is determined that it is not caused by the scraper system.

[0084] It should be noted that the interlayer thickness deviation of the subsequent layer is obtained by comparing the layer thickness of the subsequent layer with the layer thickness of the current layer thickness monitoring interval layer.

[0085] It should be noted that the acquisition methods of the single-layer, interlayer, and same-layer different position thickness deviations of the subsequent layer are the same as those of the corresponding thickness deviations of the current layer thickness monitoring interval layer.

[0086] It should be noted that the thickness deviation reduction amount is obtained by comparing the single-layer, interlayer, and same-layer different position thickness deviations of the subsequent layer with the corresponding deviations of the current layer thickness monitoring interval layer, and is recorded as the thickness deviation adjustment amount.

[0087] S3, structure integrity detection: obtaining surface crack information and internal bubble information of the intermediate printed part, judging whether the structure is complete, if the structure is complete, continuing to print and adaptively adjusting the setting of the structure monitoring interval layer according to the detection result, if the structure is not complete, terminating the printing and storing the defective printed part in the defective printed part library.

[0088] As a preferred solution, referring to Figure 3 The specific analysis process of step S3 is shown in the following.

[0089] S3.1, suspending the printer after completing the printing of the current structure monitoring interval layer.

[0090] S3.2, obtaining surface crack information including length, depth and position by optical imaging and laser scanning, and evaluating the crack defect degree.

[0091] S3.3, obtaining internal bubble information including size, density and distribution by ultrasonic detection, and evaluating the bubble defect degree.

[0092] S3.4, accumulating the crack and bubble defect degrees to obtain a comprehensive defect degree.

[0093] S3.5, comparing the comprehensive defect degree of the intermediate printed part with a preset threshold.

[0094] If the comprehensive defect degree is less than the threshold, it is determined that the structure is complete, the printing is continued, and the setting of the structure monitoring interval layer is adaptively adjusted.

[0095] If the comprehensive defect degree is greater than or equal to the threshold, it is determined that the structure is not complete, the printing is terminated, and the defective printed part is stored in the defective printed part library after marking the defect position coordinates.

[0096] It should be noted that by detecting surface cracks through optical imaging and laser scanning and detecting internal bubbles through ultrasonic waves, the dual-mode detection logic comprehensively captures explicit and implicit defects, avoids the limitations of single detection, ensures the accuracy of structural integrity judgment, and provides data support for subsequent process optimization.

[0097] It should be noted that when a small defect is detected but does not exceed the threshold, the subsequent monitoring interval layer is automatically reduced, and the detection frequency in the defect high-occurrence stage is increased. This dynamic adjustment logic can not only intercept potential risks early, but also avoid resource waste of high-frequency detection throughout the process, achieving an optimal balance between quality control and printing efficiency, and is particularly suitable for precise monitoring of key structural parts.

[0098] It should be noted that the defect coordinates are recorded and stored in the database, which can trace the correlation between high-frequency defect areas and process parameters, provide a reference for subsequent printing, and the accumulated defect data can be used to train AI models to optimize monitoring strategies, forming a closed-loop quality improvement system.

[0099] It should be noted that after the setting of the structural monitoring interval layer is dynamically adjusted, the setting of the layer thickness monitoring interval layer is also adjusted accordingly.

[0100] As a preferred solution, the specific analysis process of step S3.2 is as follows:

[0101] According to the preset rules, the scanning rod is divided into multiple regions, and a crack length threshold and a crack depth threshold are set for each region.

[0102] Based on the positions of each crack on the surface of the intermediate printed part, determine the region to which it belongs, and match the corresponding crack length threshold and crack depth threshold.

[0103] Compare the actual length and depth of each crack with the corresponding threshold.

[0104] If the length or depth of the crack exceeds the threshold, determine the defect degree of the crack according to the preset mapping relationship of defect degree when exceeding the limit.

[0105] If the length and depth of the crack do not exceed the threshold, determine the defect degree of the crack according to the preset mapping relationship of defect degree when not exceeding the limit.

[0106] Accumulate the defect degrees of all cracks to obtain the crack defect degree of the intermediate printed part.

[0107] It should be noted that the sensitivity of each region of the scanning rod to cracks is different, and the allowable threshold of cracks is also different. In one specific embodiment, the key stress region of the scanning rod is more sensitive to cracks, and the allowable threshold is lower.

[0108] It should be noted that the defect degree mapping relationship refers to a quantitative mapping relationship between the crack length and depth and the crack defect degree.

[0109] As a preferred solution, the specific analysis process of step S3.3 is as follows:

[0110] The size of each bubble inside the intermediate printed part is obtained, and the maximum bubble size is taken as the internal bubble characteristic size.

[0111] The number of bubbles in a unit volume is calculated to obtain the internal bubble density.

[0112] The distance between adjacent bubbles is measured and the average value is calculated to obtain the average distance between internal bubbles, and the internal bubble density is determined according to the preset corresponding relationship between the bubble distance and density.

[0113] The internal bubble characteristic size, density and density are input into a preset bubble defect degree evaluation model, and the bubble defect degree of the intermediate printed part is output, and the bubble defect degree evaluation model is established based on the corresponding relationship between the bubble size interval, density interval and density interval and defect degree.

[0114] As a preferred solution, the specific analysis process of step S3.5 is as follows:

[0115] A corresponding relationship between a preset comprehensive defect degree interval and a structure monitoring interval layer number reduction amount is preset.

[0116] According to the comprehensive defect degree of the intermediate printed part, the corresponding structure monitoring interval layer number reduction amount is matched.

[0117] Based on the reduction amount, the current structure monitoring interval layer number is adaptively adjusted.

[0118] In this embodiment, the present application dynamically reduces the monitoring interval according to the real-time detection result of the structural integrity, and realizes the optimal balance between quality control and printing efficiency.

[0119] S4, support removal detection: after printing is completed, the removal force, residual size and residual position when the support is removed are measured, the risk level of the influence of support residue on the function of the scanning rod is evaluated and classified, and the risk level of the influence of support residue on the function of the scanning rod is evaluated and classified.

[0120] As a preferred solution, the specific analysis process of step S4 is as follows:

[0121] After printing is completed, the removal force, residual size and residual position when the support is removed are measured.

[0122] A corresponding relationship between a removal force interval, a residual size interval and a residual position region and a risk level is preset.

[0123] According to the measured dismounting force, residual size and residual position, the corresponding risk level is matched respectively.

[0124] The highest level in each risk level is taken as the risk level of the support residual affecting the function of the scanning rod.

[0125] The hierarchical processing is performed according to the risk level.

[0126] In one specific embodiment, the correspondence between the dismounting force interval, residual size interval and residual position area and the risk level is shown in Table 1.

[0127] Table 1, correspondence between dismounting force, residual size and residual position and risk level

[0128] Evaluation dimension Mild risk Moderate risk Severe risk Disassembly force ≤3N 3-5N ＞5N Residual size ≤ 0.1 mm 0.1 - 0.3 mm ≥ 0.3 mm Residual position Non-critical area Sub-critical area Critical area

[0129] In one specific embodiment, the specific process of hierarchical processing is that the light risk can be used directly, the medium risk is used after repair, and the heavy risk is scrapped.

[0130] It should be noted that the risk level is comprehensively evaluated by the three dimensions of dismounting force, residual size and residual position, which can avoid the limitation of a single indicator and improve the comprehensiveness and accuracy of risk assessment.

[0131] It should be noted that different risk levels trigger differentiated processing strategies, which can realize optimal allocation of resources and avoid excessive processing or insufficient processing.

[0132] In the present embodiment, the present application comprehensively determines the support residual risk level by dismounting force, residual size and residual position, guides differentiated processing, and improves the usability of finished products.

[0133] In the present embodiment, the present application covers the printing full-process quality hidden danger by analyzing the layer thickness consistency, structural integrity and support residual risk.

[0134] The above formulas are dimensionless numerical calculations, and the formulas are obtained by software simulation of a large amount of data to obtain the most real situation, and the preset parameters in the formula are set by the person skilled in the art according to the actual situation.

[0135] The above embodiments can be realized by software, hardware, firmware or any combination thereof. When realized by software, the above embodiments can be realized in the form of a computer program product.

[0136] Those skilled in the art can understand that the modules and algorithm steps of each example described in combination with the embodiments disclosed herein can be realized in electronic hardware or a combination of computer software and electronic hardware. Whether the functions are realized in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to realize the described functions for each specific application, but such implementation should not be considered beyond the scope of the present application.

[0137] In addition, each functional module in each embodiment of the present application can be integrated in one processing module, or each module can exist physically alone, or two or more modules can be integrated in one module.

[0138] The above is merely specific embodiments of the present application, but the protection scope of the present application is not limited thereto, any person skilled in the art can easily think of changes or replacements within the technical scope disclosed in the present application, which should be covered in the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

[0139] Finally, the above is merely preferred embodiments of the present application, and is not used to limit the present application, any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application should be covered in the protection scope of the present application.

Claims

1. A method for 3D printing a disposable oral scanning rod, characterized in that, Includes the following steps: S1. Monitoring Interval Layer Setting: Set a structural monitoring interval layer according to the printing process and structural characteristics of the scanning rod, and set a layer thickness monitoring interval layer on the basis of the structural monitoring interval layer. Summarize and generate each printed monitoring interval layer and assign a label. The label includes layer thickness measurement, structure measurement and dual measurement. S2. Layer thickness consistency test: Perform thickness tests on the intermediate printed parts for single layers, interlayers, and different positions within the same layer. If the test is qualified, printing continues. If it is unqualified, determine whether it can be repaired based on the degree of thickness deviation and the root cause. If it can be repaired, repair it and continue printing. If it cannot be repaired, stop printing and store it in the out-of-tolerance printed parts library. S3. Structural integrity detection: Obtain surface crack information and internal bubble information of the intermediate printed part to determine whether the structure is complete. If the structure is complete, continue printing and adaptively adjust the setting of the structure monitoring interval layer according to the detection results. If it is incomplete, stop printing and store it in the defective printed part library. S4. Support Removal Inspection: After printing, measure the removal force, residual size, and residual location when removing the support. Assess the risk level of the impact of the support residue on the scanning rod function and classify the treatment accordingly.

2. The method for 3D printing a disposable oral scanning rod according to claim 1, characterized in that: The specific analysis process of step S1 is as follows: S1.1 Determine the initial stage based on the printing progress of the scanning rod; S1.2 Identify key parts based on the structural characteristics of the scanning rod. The key parts include the parts where the key structures are located and the structural connection parts. The printing stage corresponding to the key parts is recorded as the key stage, and the printing stage corresponding to the non-key parts is recorded as the regular stage. S1.

3. According to the preset rules, set the number of structural monitoring interval layers for the initial stage, key stage and regular stage in stages; S1.4 Obtain historical values ​​of the number of layers in the layer thickness monitoring interval; S1.

5. Compare the number of structural monitoring intervals at each stage with historical values ​​and calculate the similarity of the values; S1.

6. Based on numerical proximity and the cumulative number of structural monitoring interval layers, the reference value of structural monitoring interval layers for layer thickness monitoring interval layer settings at each stage is evaluated through weighted fusion. S1.

7. Fix the number of structural monitoring interval layers in the maximum reference stage to the number of layer thickness monitoring interval layers; S1.8 Summarize the structural monitoring interval layer and the layer thickness monitoring interval layer, generate each monitoring interval layer in the printing process, and assign a label to each monitoring interval layer. The label includes layer thickness measurement, structural measurement, and dual measurement.

3. The method for 3D printing a disposable oral scanning rod according to claim 1, characterized in that: The specific analysis process of step S2 is as follows: S2.1 The printer pauses after completing the printing of the current layer thickness monitoring interval layer; S2.

2. Distribute several measuring points evenly in the current layer thickness monitoring interval according to the preset rules; S2.

3. Measure the distance from each measuring point to the surface of the printing platform by probe, subtract the total theoretical thickness of the printed layers, obtain the measured layer thickness at each measuring point, and calculate the actual average layer thickness of the current layer thickness monitoring interval layer. S2.

4. Compare the actual average layer thickness of the current layer thickness detection interval with the theoretical layer thickness to obtain the single layer thickness deviation; S2.5 Compare the measured layer thickness at each measuring point, and record the maximum difference as the thickness deviation at different locations of the same layer; S2.

6. Compare the actual average thickness of the current layer thickness monitoring interval with the actual average thickness of the adjacent previous layer thickness monitoring interval to obtain the interlayer thickness deviation. S2.7 If the thickness deviation of a single layer, between layers, and at different locations within the same layer is within the set allowable range, the layer thickness consistency test is qualified and printing continues; otherwise, the test is unqualified and S2.8 is executed. S2.

8. Assess the degree of thickness deviation of the current layer thickness monitoring interval and analyze the root causes; If the deviation is less than the set threshold and the root cause is the scraper system, it is determined to be repairable, and printing continues after repair; Otherwise, it is determined to be unrepairable, printing is terminated, the current layer thickness monitoring interval layer is marked as an out-of-tolerance layer and stored in the out-of-tolerance printout library.

4. The method for 3D printing a disposable oral scanning rod according to claim 3, characterized in that: The specific method for evaluating the degree of thickness deviation in step S2.8 is as follows: The single-layer thickness deviation, inter-layer thickness deviation, and thickness deviation at different locations within the same layer of the current layer thickness monitoring interval are compared with the corresponding allowable ranges. The amount by which each deviation exceeds the allowable range is calculated and recorded as excessive thickness deviation. Based on the excessive thickness deviations at different locations within a single layer, between layers, and within the same layer, and combined with preset deviation weights, the thickness deviation degree of the current layer thickness monitoring interval layer is obtained through weighted fusion calculation.

5. The method for 3D printing a disposable oral scanning rod according to claim 3, characterized in that: The method for analyzing the root cause of thickness deviation in step S2.8 is as follows: Adjust the printer's scraper system and continue printing the next layer after the current layer thickness monitoring interval as the subsequent layer; After printing, the thickness deviation of subsequent layers at different positions, including single layer, interlayer, and same layer, is measured and compared with the corresponding deviation of the current layer thickness monitoring interval layer to calculate the thickness deviation correction amount. Based on the thickness deviation callback amount, and combined with the preset quantitative mapping relationship between the thickness deviation callback amount and the adjustment effect, the trial adjustment effect of the scraper system is evaluated. If the adjustment effect reaches the preset expected value, the adjustment is effective, and the root cause of the current layer thickness monitoring interval layer thickness deviation is determined to be the scraper system; Otherwise, if the adjustment is ineffective, the cause is determined to be something other than the scraper system.

6. The method for 3D printing a disposable oral scanning rod according to claim 1, characterized in that: The specific analysis process of step S3 is as follows: S3.1 Pause the printer after completing the printing of the current structural monitoring interval layer; S3.2 Obtain surface crack information, including length, depth and location, through optical imaging and laser scanning, and assess the degree of crack defects; S3.3 Obtain internal bubble information, including size, density and distribution, through ultrasonic testing to assess the degree of bubble defects; S3.

4. The overall defect level is obtained by summing the crack and bubble defect levels; S3.

5. Compare the overall defect level of the intermediate printed part with the preset threshold. If the value is less than the threshold, the structure is determined to be intact, printing continues and the structure monitoring interval layer setting is adaptively adjusted. If the value is greater than or equal to the threshold, the structure is determined to be incomplete. Printing is terminated, and the coordinates of the defect location are marked and then stored in the defect printout library.

7. The method for 3D printing a disposable oral scanning rod according to claim 6, characterized in that: The specific analysis process of step S3.2 is as follows: The scanning rod is divided into multiple regions according to preset rules, and crack length threshold and crack depth threshold are set for each region. Based on the location of each crack on the surface of the intermediate printed part, determine its region and match the corresponding crack length threshold and crack depth threshold. The actual length and depth of each crack are compared with the corresponding threshold. If the length or depth of the crack exceeds the threshold, the defect degree of the crack is determined according to the preset over-limit defect degree mapping relationship. If the length and depth of the crack do not exceed the threshold, the defect degree of the crack is determined according to the preset non-exceeding time defect degree mapping relationship. The defect severity of all cracks is summed to obtain the crack defect severity of the intermediate printed part.

8. The method for 3D printing a disposable oral scanning rod according to claim 6, characterized in that: The specific analysis process of step S3.3 is as follows: Obtain the dimensions of each bubble inside the intermediate printed part, and use the largest bubble size as the feature size of the internal bubble; Calculate the number of bubbles per unit volume to obtain the internal bubble density; Measure the distance between adjacent bubbles and calculate their average value to obtain the average distance between internal bubbles. Then, determine the density of internal bubbles based on the preset correspondence between bubble distance and density. The internal bubble feature size, density, and concentration are input into a preset bubble defect degree evaluation model, and the bubble defect degree of the intermediate printed part is output. The bubble defect degree evaluation model is established based on the correspondence between bubble size range, density range, and concentration range and defect degree.

9. A method for 3D printing a disposable oral scanning rod according to claim 6, characterized in that: The specific analysis process of step S3.5 is as follows: The correspondence between the preset comprehensive defect severity range and the reduction in the number of layers of structural monitoring intervals; Based on the overall defect severity of the intermediate printed parts, adjust the corresponding structural monitoring interval layer reduction amount accordingly; The number of layers in the current structural monitoring interval is adaptively adjusted based on the aforementioned reduction amount.

10. The method for 3D printing a disposable oral scanning rod according to claim 1, characterized in that: The specific analysis process of step S4 is as follows: After printing, measure the removal force, residual size, and residual location when the support is removed; The correspondence between the preset demolition force range, residual size range, residual location area and risk level; Based on the measured demolition force, residual size, and residual location, the corresponding risk level is matched accordingly; The highest risk level among all risk levels is taken as the risk level of the impact of support residue on the scanning rod function; The risk level will be classified and processed accordingly.

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