Spring metal 3D printing method based on rotating stairs

Abstract

The application relates to the technical field of metal 3D printing, and discloses a spring metal 3D printing method based on a rotating staircase, which comprises the following steps: setting a maximum unsupported suspension distance of a target spring, and simultaneously obtaining the total height and the medium diameter of the target spring; setting the horizontal rotation angle of a square unit required for constituting the target spring, and setting the thickness of the square unit and the pitch of the target spring; calculating the total number of the square units based on the total height, the preset pitch and the horizontal rotation angle; verifying the rationality of the target spring according to the total number, the thickness and the total height; if the verification is passed, setting the rotation axis of the target spring according to the medium diameter to discretize the target spring, generating a space digital model, and controlling a metal 3D printing device to print the square units in the space digital model as slice layers for layer-by-layer stacking. The whole spring is always in the unsupported suspension range that can be realized by the metal 3D printing device in the printing process, and the spring can be directly printed without support.

Description

Technical Field

[0001] This invention relates to the field of metal 3D printing technology, and in particular to a method for 3D printing springs based on a spiral staircase. Background Technology

[0002] In metal additive manufacturing, selective laser melting (SLM) has garnered significant attention due to its unique advantages in fabricating lightweight, functionally integrated components with complex geometries. However, this technology faces substantial technical bottlenecks when applied to the fabrication of helical spatial curved surface structures, such as metal springs.

[0003] Due to the inherent helical geometry of springs, their helix angle is typically smaller than the limit angle that metal additive manufacturing equipment can successfully produce in an unsupported state. This limit angle usually refers to the minimum angle between the forming surface and the substrate plane. Therefore, when directly printing metal springs using existing conventional methods, to avoid printing failures in the overhanging area, a large number of support structures must be generated and printed below and even inside the spring coil. These necessary support structures need to be removed mechanically after printing. This post-processing is not only cumbersome and time-consuming, significantly increasing manufacturing costs and cycle time, but more seriously, the removal of support structures can easily cause irreversible damage such as scratches and deformation to the surface of the spring coil, directly affecting the spring's fatigue life, mechanical properties, and dimensional accuracy.

[0004] To circumvent the aforementioned support issues, some alternative solutions exist in existing technologies, such as printing the spring structure in segments before assembling them, or printing a blank of approximate shape first and then obtaining the final contour through subsequent machining. However, these methods deviate from the core idea of ​​integrated additive manufacturing, leading to a more complex manufacturing process and potentially introducing weak connection areas or material losses, making it difficult to achieve efficient, precise, and integrated manufacturing of high-performance metal springs.

[0005] Therefore, there is an urgent need for innovative methods that can achieve unsupported, integrated additive manufacturing of metal springs to solve a series of problems caused by support structures and fully unleash the application potential of additive manufacturing technology in the field of complex elastic elements. Summary of the Invention

[0006] This invention provides a method for metal 3D printing of springs based on a spiral staircase, which solves the problem that springs cannot be directly formed without support during the metal 3D printing process. Through an innovative geometric design method, the entire spring is kept within the unsupported suspension range achievable by the metal 3D printing equipment during the printing process, thereby realizing the direct printing of springs without support.

[0007] This invention provides a method for 3D printing metal springs based on a spiral staircase, comprising:

[0008] S1. Based on the performance of the metal 3D printing equipment, set the maximum unsupported suspension distance of the target spring. Simultaneously, the total height H and mean diameter D of the target spring are obtained;

[0009] S2. Set the horizontal rotation angle θ of the block unit required to form the target spring, and set the thickness Δh of the block unit and the pitch p of the target spring according to the mechanical performance requirements of the target spring;

[0010] S3. Based on the total height H of the target spring, the preset pitch p, and the horizontal rotation angle θ, calculate the total number n of the block units;

[0011] S4. Verify the rationality of the target spring based on the total number n, thickness Δh, and total height H of the block units. If the verification fails, return to step S2. If the verification passes, proceed to step S5.

[0012] S5. Set the rotation axis of the target spring according to the mean diameter D, and based on the rotation axis, the total number n, and the maximum unsupported suspension distance... Discretize the target spring to generate a spatial digital model;

[0013] S6. Import the spatial digital model into the metal 3D printing equipment, and control the metal 3D printing equipment to stack and print the block units in the spatial digital model as slice layers one by one.

[0014] Furthermore, S3 specifically includes:

[0015] S301. Calculate the total number of coils k of the target spring based on the total height H of the target spring and the preset pitch p. The calculation formula is: k=H / p;

[0016] S302. Calculate the total rotation angle A of the target spring based on the total number of coils k of the target spring. The calculation formula is: A = 360° × k.

[0017] S303. Calculate the total number of block units n based on the horizontal rotation angle θ and the total rotation angle A. The calculation formula is: n = A / θ.

[0018] Furthermore, S4 specifically includes:

[0019] S401. Calculate the theoretical number of the block units n*=H / △h, and determine whether the difference between the theoretical number n* and the total number n is within a preset range.

[0020] S402. If the difference between the theoretical quantity n* and the total quantity n is not within the preset range, return to step S2 to adjust the horizontal rotation angle θ, or adjust the thickness △h of the block unit.

[0021] S403. If the difference between the theoretical quantity n* and the total quantity n is within a preset range, then proceed to step S5.

[0022] Furthermore, S5 specifically includes:

[0023] S501. Set the rotation axis of the target spring according to the mean diameter D, and discretize the target spring into continuous block units based on the rotation axis and the total number n to form a spiral staircase-like spatial configuration.

[0024] S502. Calculate the maximum lateral floating distance Δd between adjacent square units, and verify whether Δd ≤ If the conditions are not met, return to S2 to adjust the parameters; if the conditions are met, generate a spatial digital model.

[0025] Furthermore, in S501, the distance from the block unit to the rotation axis is a fixed distance, and the fixed distance is D / 2.

[0026] Furthermore, the shape of the block unit is fan-shaped.

[0027] The present invention also provides a spring metal 3D printing device based on a spiral staircase, which, based on the spring metal 3D printing method based on a spiral staircase as described above, includes:

[0028] The acquisition module is used to set the maximum unsupported suspension distance of the target spring based on the performance of the metal 3D printing equipment. Simultaneously, the total height H and mean diameter D of the target spring are obtained;

[0029] The setting module is used to set the horizontal rotation angle θ of the block unit required to form the target spring, and to set the thickness Δh of the block unit and the pitch p of the target spring according to the mechanical performance requirements of the target spring.

[0030] The calculation module is used to calculate the total number n of the block units based on the total height H of the target spring, the preset pitch p, and the horizontal rotation angle θ.

[0031] The verification module is used to verify the rationality of the target spring based on the total number n, thickness Δh, and total height H of the block units. If the verification fails, it returns to step S2; if the verification passes, it proceeds to step S5.

[0032] The generation module is used to set the rotation axis of the target spring according to the mean diameter D, based on the rotation axis, the total number n, and the maximum unsupported suspension distance. Discretize the target spring to generate a spatial digital model;

[0033] The printing module is used to import the spatial digital model into the metal 3D printing equipment and control the metal 3D printing equipment to stack and print the block units in the spatial digital model as slice layers one by one.

[0034] The present invention also provides a computer device, including a memory and a processor, wherein the memory stores a computer program, and the processor executes the computer program to implement the steps of the above-described method.

[0035] The present invention also provides a computer-readable storage medium having a computer program stored thereon, wherein the computer program, when executed by a processor, implements the steps of the above-described method.

[0036] The beneficial effects of this invention are as follows:

[0037] This invention achieves unsupported, integrated molding of metal springs through a unique geometric design, eliminating the cumbersome support removal process and its potential damage to the spring surface. This self-supporting structure effectively suppresses common defects during printing, such as collapse and overheating, significantly improving the stability of the molding process and the geometric accuracy and mechanical properties of the components. Simultaneously, this method greatly simplifies the overall process flow from design to molding, reducing manufacturing costs and cycle time. Through parametric driving, it can flexibly adapt to spring designs with different dimensions and helix angles, exhibiting excellent versatility. Ultimately, this invention provides a novel and efficient design approach and implementation method for additive manufacturing of metal elastic elements, breaking through long-standing technical bottlenecks in this field. Attached Figure Description

[0038] Figure 1 This is a schematic diagram of a method flow according to an embodiment of the present invention.

[0039] Figure 2 This is a schematic diagram of the device structure according to an embodiment of the present invention.

[0040] Figure 3 This is a schematic diagram of the internal structure of a computer device according to an embodiment of the present invention.

[0041] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0042] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0043] This invention establishes a spatial digital model of a spring helical curve, discretizes it into several sector-shaped square units, and each square rises a certain height (e.g., 0.04 mm, corresponding to the printing layer thickness) in the vertical direction relative to the next square, and rotates in the horizontal direction at a fixed angle (e.g., 1.2°), thereby forming a continuously rising "spiral staircase" spatial path, realizing a geometric configuration that can be stacked layer by layer and is self-supporting.

[0044] like Figure 1 As shown, this invention provides a method for 3D printing metal springs based on a spiral staircase, comprising:

[0045] S1. Based on the performance of the metal 3D printing equipment, set the maximum unsupported suspension distance of the target spring. Simultaneously, the total height H and mean diameter D of the target spring are obtained;

[0046] S2. Set the horizontal rotation angle θ of the block unit (preferably fan-shaped) required to form the target spring, and set the thickness Δh of the block unit and the pitch p of the target spring according to the mechanical performance requirements of the target spring;

[0047] S3. Based on the total height H of the target spring, the preset pitch p, and the horizontal rotation angle θ, calculate the total number n of the block units;

[0048] S4. Verify the rationality of the target spring based on the total number n, thickness Δh, and total height H of the block units. If the verification fails, return to step S2. If the verification passes, proceed to step S5.

[0049] S5. Set the rotation axis of the target spring according to the mean diameter D, and based on the rotation axis, the total number n, and the maximum unsupported suspension distance... Discretize the target spring to generate a spatial digital model;

[0050] S6. Import the spatial digital model into the metal 3D printing equipment, and control the metal 3D printing equipment to stack and print the block units in the spatial digital model as slice layers one by one.

[0051] As described in steps S1-S6 above, based on the process capabilities of the selected metal 3D printing equipment (such as SLM), the characteristics of the metal material used, and the optimized printing parameters, a key process limit is set, namely the maximum unsupported suspension distance. This distance represents the misalignment distance between two adjacent block units. This distance value is an empirical value obtained based on a large number of process experiments, ensuring that any overhanging structure smaller than this distance can be reliably printed. Simultaneously, based on the functional requirements of the spring, the macroscopic geometric parameters of the target spring are obtained, namely the total height H and the mean diameter D. A fixed angle θ is set for the rotation of each block unit constituting the spring around its central axis in the horizontal plane. The smaller this angle, the smoother the final spiral path, but the larger the model data volume. Based on the standard layer thickness of the printing equipment and the manufacturing efficiency of the spring, the thickness Δh of the block unit is set, which directly corresponds to the single-layer powder thickness of the printer. Based on the mechanical performance requirements (such as stiffness) of the target spring, the spring pitch p is preset. The pitch is a key parameter determining the spring's density and mechanical behavior. Based on the parameters (H, p, θ) determined in steps S1 and S2, a series of calculations are performed to convert the continuous number of spiral turns into a discrete, executable number of blocks, which is the basis of digital modeling. Then, the parameter combinations generated in steps S2 and S3 are double-verified, including geometric consistency verification: checking whether the total height (n×Δh) calculated from the total number n and thickness Δh is consistent with or approximately equal to the target total height H to ensure accurate model dimensions. Self-supporting feasibility verification: estimating the maximum lateral suspension distance Δd between adjacent block elements based on the current parameters (especially θ and p), and determining whether it satisfies Δd≤Lmax. If any verification fails, it indicates that the current parameter combination is unreasonable (e.g., the pitch is too small, resulting in excessive steepness and inability to self-support). The system will return to step S2, prompting the user to adjust parameters such as the horizontal rotation angle θ or the pitch p, and then recalculate and verify until all conditions are met. This iterative process ensures the rationality and printability of the final model. Based on the median diameter D, a cylindrical envelope surface with a radius of D / 2 is established in virtual space with the Z-axis as the rotation axis. Based on the verified parameters (total number n, rotation angle θ, thickness Δh), n sector block elements are generated sequentially from the starting point. Each unit, based on the position of the previous unit, undergoes a transformation of "rising Δh" and "rotating θ". All these units are connected end-to-end, forming a "spiral staircase"-like spatial path that spirals upwards along the cylindrical surface around the rotation axis, resulting in the final, self-supporting digital model of the spring. The digital model generated in step S5, ensuring the feasibility of unsupported printing, is imported into the metal 3D printing equipment. The printer control system directly recognizes each cube unit in the model as an independent slice layer. The equipment, through layer-by-layer powder spreading and selective laser melting, strictly follows the geometric instructions of the model to stack and metallurgically bond these cube units, ultimately directly manufacturing a complete metal spring part without any auxiliary support structure.

[0052] In one embodiment, S3 specifically includes:

[0053] S301. Calculate the total number of coils k of the target spring based on the total height H of the target spring and the preset pitch p. The calculation formula is: k=H / p; where the larger the pitch p is, the fewer the number of coils and the smaller the total rotation angle A; the smaller the pitch p is, the more the number of coils and the larger the total rotation angle A; the pitch parameter thus determines the longitudinal ascent rate and overall torsional amplitude of the entire "spiral staircase" structure.

[0054] S302. Calculate the total rotation angle A of the target spring based on the total number of coils k of the target spring. The calculation formula is: A = 360° × k.

[0055] S303. Calculate the total number of block units n based on the horizontal rotation angle θ and the total rotation angle A. The calculation formula is: n = A / θ. For example, when p = 12mm, k = 3 rotations, and θ = 1.2°, A = 1080°, and the number of blocks n = 1080 / 1.2 = 900. In practice, 910 is used, indicating that 10 blocks are added to the theoretical minimum number of blocks (900), reducing the single-step angle and step length, and reserving a safety margin for unsupported overhang and processing errors.

[0056] As described in steps S301-S303 above, the total number of spring coils k is calculated based on the target total spring height H and preset pitch p determined in previous steps. The calculation formula is: k = H / p; the influence of p on k can be directly derived from the formula. Under the premise of a fixed total height H, the larger the preset pitch p, the smaller the calculated total number of coils k; conversely, the smaller the preset pitch p, the larger the total number of coils k. This step establishes the basic topology of the spring. Pitch p, as a key design variable, directly determines the density of the spring coils, thus laying the foundation for the subsequent calculation of the total rotation amplitude. Based on the total number of coils k calculated in step S301, the total angle A of the rotation of the spring helix around the central axis from the starting point to the ending point is calculated. The calculation formula is: A = 360° × k; the total rotation angle A is proportional to the total number of coils k. Combining the conclusion of step S301, it can be seen that the larger the pitch p, the smaller the total number of coils k, and therefore the smaller the total rotation angle A; the smaller the pitch p, the more total coils k, and the larger the total rotation angle A. The total rotation angle A quantifies the total torsional amplitude of the entire spring structure in space. The pitch parameter p therefore plays a dual role, determining not only the longitudinal rate of ascent of the spring but also, by influencing the total rotation angle A, the overall torsional amplitude of the entire "spiral staircase" structure. Based on the total rotation angle A calculated in step S302 and the horizontal rotation angle θ of a single block unit set in a previous step, the total number of block units n required to construct the entire spring model is calculated. The formula is: n = A / θ; this step yields the specific, executable number of modeling instructions. Determining the total number of blocks n means that the continuous geometry of the spring has been precisely described by a stackable path consisting of n discrete steps, providing the fundamental data basis for generating a self-supporting digital model that can be directly used for 3D printing.

[0057] In one embodiment, S4 specifically includes:

[0058] S401. Calculate the theoretical number of the block units n*=H / △h, and determine whether the difference between the theoretical number n* and the total number n is within a preset range.

[0059] S402. If the difference between the theoretical quantity n* and the total quantity n is not within the preset range, return to step S2 to adjust the horizontal rotation angle θ, or adjust the thickness △h of the block unit.

[0060] S403. If the difference between the theoretical quantity n* and the total quantity n is within a preset range, then proceed to step S5.

[0061] As described in steps S401-S403 above, the theoretical quantity n* is calculated. Based on the basic physical principles of spring manufacturing, i.e., the total height is accumulated from the layer thickness and the number of layers, the theoretical quantity n* of the block unit is calculated. The formula is: n* = H / Δh; representing the number of printed layers required to achieve the total height H with a given layer thickness Δh, based on the physics of vertical stacking. The calculated theoretical quantity n* is compared with the total quantity n calculated in step S3 based on the geometric rotation relationship (n = A / θ), and it is determined whether the difference between the two is within a preset allowable range. The judgment criterion is that this preset range usually takes into account the small errors caused by rounding in the calculation, for example, allowing |n*-n|≤1. The fundamental purpose is to ensure that n×Δh≈H, that is, the actual stacking height of the model must be infinitely close to the design target H. If the judgment result of S401 indicates that the difference is not within the preset range, it means that there is a contradiction in the current parameter set, and a model with accurate dimensions cannot be generated. The parameter adjustment iteration must be initiated, i.e., returning to step S2, to adjust key parameters and restore the consistency of the parameter system while ensuring the spring's function (mechanical performance) and manufacturing feasibility (self-support). Adjustment strategies include: prioritizing the adjustment of the horizontal rotation angle θ, which is the preferred and least impactful strategy. Fine-tuning θ directly changes the total quantity n calculated geometrically, without affecting the preset layer thickness Δh of the printing equipment or the pitch p that determines the spring's performance. By finely adjusting θ, n can be brought closer to n*, thus satisfying the consistency condition. Secondly, the block unit thickness Δh can be adjusted. Since Δh is usually bound to the standardized process parameters of the printing equipment, changing it may require re-verification of process stability. However, in some cases, fine-tuning Δh to bring the theoretical quantity n* closer to the total quantity n is also a feasible solution. If the judgment result of S401 is that the difference is within the preset range, it proves that all parameters (H,p,θ,Δh,n) are in a harmonious and consistent state, and proceed to step S5 to generate the final spatial digital model based on the verified parameters.

[0062] In one embodiment, S5 specifically includes:

[0063] S501. Set the rotation axis of the target spring according to the mean diameter D (the distance from the block unit to the rotation axis is a fixed distance D / 2). Based on the rotation axis and the total number n, discretize the target spring into continuous block units to form a spiral staircase-like spatial configuration.

[0064] S502. Calculate the maximum lateral floating distance Δd between adjacent square units, and verify whether Δd ≤ If the conditions are not met, return to S2 to adjust the parameters; if the conditions are met, generate a spatial digital model. The maximum floating distance of each block unit (e.g., 0.18 mm) is controlled within the unsupported floating limit range of the metal 3D printing equipment (such as the EP-M series) at a specified layer thickness (0.04 mm), ensuring that the blocks overlap layer by layer and support each other step by step, thereby realizing the unsupported direct printing of metal springs.

[0065] As described in steps S501-S502 above, in the virtual space of a computer-aided design system or dedicated modeling software, a fixed vertical axis is set as the rotation center axis of the entire spring model based on the mean diameter D of the target spring. A starting point is determined on the rotation axis, and the first sector block unit is placed here, with its outer edge maintaining a fixed radial distance D / 2 from the rotation axis to ensure the formation of the spring's inner diameter. Based on the total number n of block units calculated in step S3, iterative generation is performed. Starting from the first block, each subsequent block performs a fixed three-dimensional transformation based on the position of the previous block: first, it rotates horizontally around the rotation axis by an angle θ, and then rises vertically along the rotation axis by a height Δh. By continuously performing this transformation n times, n sector block units are generated, stacked one after another. These units together form a path that spirals upward around the central axis in space, i.e., a "spiral staircase" spatial geometric configuration, which is macroscopically represented as the spiral shape of the target spring. Based on the specific geometric model generated in S501, the maximum lateral suspension distance Δd between adjacent block units is calculated. This distance is the most direct indicator for assessing the risk of unsupported printing, quantifying the degree to which the upper layer of blocks is suspended relative to the lower layer. The calculated maximum lateral suspension distance Δd is then compared with the maximum unsupported suspension limit set in step S1, which represents the equipment's process capability. The comparison and verification are based on the condition: Δd ≤ If Δd > If the current generated model structure is too steep, it indicates a risk of collapse during printing. The process will return to step S2, where the pitch p (increasing p makes the helix smoother) or the horizontal rotation angle θ will be adjusted first, and then subsequent calculations and modeling will be performed again until this critical condition is met. If Δd≤ This proves that the "spiral staircase" configuration is entirely within the supportless manufacturing capabilities of metal 3D printing equipment. Each block unit can be effectively supported by the block directly below it, achieving a self-supporting effect of layer-by-layer overlapping and step-by-step support, formally generating the final spatial digital model, which is ready to drive the printing equipment.

[0066] This invention primarily targets metal powder materials (such as Inconel 718). Different materials exhibit slight differences in molten pool characteristics and suspension limit angles, which can be adapted by adjusting the rise height and angle of each block. Optimal parameters can be fine-tuned based on the printing equipment model and material characteristics (such as laser power, scanning speed, layer thickness, etc.).

[0067] This invention can be widely applied to: the manufacture of miniature springs in micro gas turbines and aero engines; metal spring components in precision instruments, sensors, valves, and high-temperature, high-load environments; metal additive manufacturing design optimization and research on unsupported printed structures; and the fields of education, scientific research, and additive design innovation verification. Its application involves designing a spring model using a segmented, "spiral staircase" stacking structure in 3D printing modeling software (such as SolidWorks or Magics), and then directly printing it using a metal 3D printer (such as the EasyPlus EP-M series).

[0068] In this specific example, the total height of the spring is set to 36mm, the pitch to 12mm, and the number of spiral turns to 3. There are 910 sector-shaped blocks; each block has a height of 0.32mm and an angle of 1.2°. The outer diameter of the spring is 17.20mm, and the inner diameter is 13.20mm. The maximum levitation distance of each small block is 0.18mm, controlled within the limit range (0.5mm) of unsupported levitation printing achievable by metal 3D printing equipment. The overall spring model constructed in this way has a continuous geometric shape and can be stacked layer by layer during printing, supporting its own structure without the need for additional supports, allowing for direct printing.

[0069] like Figure 2 As shown, the present invention also provides a spring metal 3D printing device based on a spiral staircase, and based on the spring metal 3D printing method based on a spiral staircase as described above, the device includes:

[0070] The acquisition module is used to set the maximum unsupported suspension distance of the target spring based on the performance of the metal 3D printing equipment. Simultaneously, the total height H and mean diameter D of the target spring are obtained;

[0071] The setting module is used to set the horizontal rotation angle θ of the block unit required to form the target spring, and to set the thickness Δh of the block unit and the pitch p of the target spring according to the mechanical performance requirements of the target spring.

[0072] The calculation module is used to calculate the total number n of the block units based on the total height H of the target spring, the preset pitch p, and the horizontal rotation angle θ.

[0073] The verification module is used to verify the rationality of the target spring based on the total number n, thickness Δh, and total height H of the block units. If the verification fails, it returns to step S2; if the verification passes, it proceeds to step S5.

[0074] The generation module is used to set the rotation axis of the target spring according to the mean diameter D, based on the rotation axis, the total number n, and the maximum unsupported suspension distance. Discretize the target spring to generate a spatial digital model;

[0075] The printing module is used to import the spatial digital model into the metal 3D printing equipment and control the metal 3D printing equipment to stack and print the block units in the spatial digital model as slice layers one by one.

[0076] Each of the above modules is used to perform the respective steps in the above-described method for 3D printing spring metal based on a spiral staircase. The specific implementation method is as described in the above-described method embodiments, and will not be repeated here.

[0077] like Figure 3 As shown, the present invention also provides a computer device, which may be a server, and its internal structure may be as follows: Figure 3 As shown, the computer device includes a processor, memory, network interface, and database connected via a system bus. The processor provides computational and control capabilities. The memory includes non-volatile storage media and internal memory. The non-volatile storage media stores the operating system, computer programs, and database. The internal memory provides the environment for the operation of the operating system and computer programs stored in the non-volatile storage media. The database stores all data required for the process of the spiral staircase-based spring metal 3D printing method. The network interface is used for communication with external terminals via a network connection. The computer program is executed by the processor to implement the spiral staircase-based spring metal 3D printing method.

[0078] Those skilled in the art will understand that Figure 3 The structure shown is merely a block diagram of a portion of the structure related to the present application and does not constitute a limitation on the computer equipment on which the present application is applied.

[0079] An embodiment of this application also provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements any of the above-described spring metal 3D printing methods based on a spiral staircase.

[0080] Those skilled in the art will understand that all or part of the processes in the methods of the above embodiments can be implemented by hardware related to computer program instructions. The computer program can be stored in a non-volatile computer-readable storage medium, and when executed, it can include the processes of the above method embodiments. Any references to memory, storage, databases, or other media provided in this application and used in the embodiments can include non-volatile and / or volatile memory. Non-volatile memory can include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM), or flash memory. Volatile memory can include random access memory (RAM), such as dynamic RAM (used as main storage) or static RAM (commonly used as cache memory). By way of illustration and not limitation, RAM has various forms, such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rate SDRAM (DDR SDRAM), and Rambus DRAM (RDRAM).

[0081] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, apparatus, article, or method that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, apparatus, article, or method. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, apparatus, article, or method that includes that element.

[0082] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A method for 3D printing metal springs based on a spiral staircase, characterized in that, include: S1. Based on the performance of the metal 3D printing equipment, set the maximum unsupported suspension distance of the target spring. Simultaneously, the total height H and mean diameter D of the target spring are obtained; S2. Set the horizontal rotation angle θ of the block unit required to form the target spring, and set the thickness Δh of the block unit and the pitch p of the target spring according to the mechanical performance requirements of the target spring; S3. Based on the total height H of the target spring, the preset pitch p, and the horizontal rotation angle θ, calculate the total number n of the block units; S4. Verify the rationality of the target spring based on the total number n, thickness Δh, and total height H of the block units. If the verification fails, return to step S2. If the verification passes, proceed to step S5. S5. Set the rotation axis of the target spring according to the mean diameter D, and based on the rotation axis, the total number n, and the maximum unsupported suspension distance... Discretize the target spring to generate a spatial digital model; S6. Import the spatial digital model into the metal 3D printing equipment, and control the metal 3D printing equipment to stack and print the block units in the spatial digital model as slice layers one by one.

2. The method for 3D printing spring metal based on a spiral staircase according to claim 1, characterized in that, S3 specifically includes: S301. Calculate the total number of coils k of the target spring based on the total height H of the target spring and the preset pitch p. The calculation formula is: k=H / p; S302. Calculate the total rotation angle A of the target spring based on the total number of coils k of the target spring. The calculation formula is: A = 360° × k. S303. Calculate the total number of block units n based on the horizontal rotation angle θ and the total rotation angle A. The calculation formula is: n = A / θ.

3. The method for 3D printing spring metal based on a spiral staircase according to claim 1, characterized in that, S4 specifically includes: S401. Calculate the theoretical number of the block units n*=H / △h, and determine whether the difference between the theoretical number n* and the total number n is within a preset range. S402. If the difference between the theoretical quantity n* and the total quantity n is not within the preset range, return to step S2 to adjust the horizontal rotation angle θ, or adjust the thickness △h of the block unit. S403. If the difference between the theoretical quantity n* and the total quantity n is within a preset range, then proceed to step S5.

4. The method for 3D printing spring metal based on a spiral staircase according to claim 1, characterized in that, S5 specifically includes: S501. Set the rotation axis of the target spring according to the mean diameter D, and discretize the target spring into continuous block units based on the rotation axis and the total number n to form a spiral staircase-like spatial configuration. S502. Calculate the maximum lateral floating distance Δd between adjacent square units, and verify whether Δd ≤ If the conditions are not met, return to S2 to adjust the parameters; if the conditions are met, generate a spatial digital model.

5. The method for 3D printing spring metal based on a spiral staircase according to claim 1, characterized in that, In step S501, the distance from the block unit to the rotation axis is a fixed distance, which is D / 2.

6. The method for 3D printing spring metal based on a spiral staircase according to claim 1, characterized in that, The square unit is fan-shaped.

7. A 3D printing apparatus for spring metal based on a spiral staircase, based on the 3D printing method for spring metal based on a spiral staircase according to any one of claims 1-5, characterized in that, The device includes: The acquisition module is used to set the maximum unsupported suspension distance of the target spring based on the performance of the metal 3D printing equipment. Simultaneously, the total height H and mean diameter D of the target spring are obtained; The setting module is used to set the horizontal rotation angle θ of the block unit required to form the target spring, and to set the thickness Δh of the block unit and the pitch p of the target spring according to the mechanical performance requirements of the target spring. The calculation module is used to calculate the total number n of the block units based on the total height H of the target spring, the preset pitch p, and the horizontal rotation angle θ. The verification module is used to verify the rationality of the target spring based on the total number n, thickness Δh, and total height H of the block units. If the verification fails, it returns to step S2; if the verification passes, it proceeds to step S5. The generation module is used to set the rotation axis of the target spring according to the mean diameter D, based on the rotation axis, the total number n, and the maximum unsupported suspension distance. Discretize the target spring to generate a spatial digital model; The printing module is used to import the spatial digital model into the metal 3D printing equipment and control the metal 3D printing equipment to stack and print the block units in the spatial digital model as slice layers one by one.

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