Neovius-gyroid multilayer composite thermal insulation element and additive manufacturing method thereof

Abstract

Provided are a Neovius-Gyroid multilayer composite thermal insulation component and an additive manufacturing method thereof, wherein a Neovius structure and a Gyroid structure are respectively constructed, a solid region of the Neovius structure is separated by geometric topology analysis, the solid region is respectively subjected to Boolean operation with the Neovius structure and the Gyroid structure, a Neovius load-bearing skeleton structure is constructed and formed, and a Gyroid filler body with a consistent morphology is synchronously generated, then a Neovius-Gyroid multilayer composite thermal insulation structure with connected pores is generated by Boolean union operation, and then the multilayer composite thermal insulation structure is subjected to slicing processing, layer-by-layer scanning path data is generated, and a powder bed additive manufacturing process is used to realize synchronous integrated forming of the skeleton and the filler body in the same forming cycle, thereby completing the construction of the Neovius-Gyroid multilayer composite thermal insulation component. The application can use an additive manufacturing process to manufacture an overall composite structure with light weight and thermal insulation performance, and solve the problems of serious connection thermal bridge effect and large weight of traditional thermal insulation structures.

Description

Technical Field

[0001] This application relates to the field of additive manufacturing technology, and more specifically to a Neovius-Gyroid multilayer composite thermal insulation component and its additive manufacturing method. Background Technology

[0002] In aerospace, power energy, and other fields, core equipment is moving towards higher efficiency and lighter weight. In intermediate-temperature service environments, airframe structural components often face stringent requirements for both mechanical load-bearing capacity and thermal management, necessitating both high specific strength and excellent thermal insulation performance.

[0003] Currently, most existing thermal insulation load-bearing components adopt traditional honeycomb and truss structures. These traditional structures have significant drawbacks. First, the mechanical properties of traditional honeycomb or truss structures are limited under load and impact, making it difficult to maintain stable platform stress. Second, mechanical connections inevitably introduce additional non-functional weight, and metal connectors are prone to forming serious heat transfer channels, thereby significantly reducing the overall thermal protection efficiency. Therefore, how to eliminate the thermal bridging effect and structural redundancy caused by traditional mechanical assembly, and achieve lightweight components and integrated load-bearing and thermal insulation functions under medium-temperature conditions, is a huge challenge we are currently facing.

[0004] In recent years, additive manufacturing porous structures using triple minimal surface modulus (TPMS) have gradually attracted attention due to their continuous and smooth surface characteristics. However, existing research and applications have mostly focused on the parameter optimization of a single TPMS configuration, such as improving structural strength or thermal performance by adjusting unit size or wall thickness. When increasing the wall thickness to improve load-bearing capacity, the effective thermal conductivity of such a single TPMS structure increases, and the thermal insulation performance decreases significantly. Conversely, when increasing porosity to reduce thermal conductivity, the structural stiffness and stability are significantly weakened. Therefore, it is difficult for a single TPMS structure to balance mechanical and thermal performance, thereby weakening the thermal insulation effect and increasing weight. Summary of the Invention

[0005] This application provides a Neovius-Gyroid multilayer composite thermal insulation component and its additive manufacturing method. By using implicit functions to construct a single Neovius and Gyroid structure and through spatial Boolean operations, the Gyroid filler is precisely nested in the internal cavity of the Neovius support skeleton to construct a multilayer composite thermal insulation component. Then, additive manufacturing process is used to integrally form it, realizing efficient spatial distribution of materials and combining lightweight, high strength and excellent thermal insulation performance.

[0006] In a first aspect, this application provides an additive manufacturing method for a Neovius-Gyroid multi-level composite thermal insulation component. The method includes: constructing a Neovius structure and a Gyroid structure respectively, and based on the geometric characteristics of the Neovius structure, using geometric topology analysis to separate the solid regions of the Neovius structure, including the body center, face center, edges, and vertices; performing Boolean subtraction and Boolean intersection operations on the solid regions with the Neovius structure and the Gyroid structure respectively, to construct a Neovius load-bearing skeleton structure with a continuous curved surface, and forming a cavity within the Neovius load-bearing skeleton structure, and simultaneously generating... A Gyroid filler with a consistent shape is used; a Boolean union operation is performed on the Neovius load-bearing skeleton structure and the Gyroid filler to generate a Neovius-Gyroid multi-level composite thermal insulation structure with interconnected pores; and the Neovius-Gyroid multi-level composite thermal insulation structure is sliced ​​to generate layer-by-layer scanning path data. A preset additive manufacturing process is used to simultaneously melt and metallurgically bond the Neovius load-bearing skeleton structure and the Gyroid filler layer by layer within the same forming cycle according to the layer-by-layer scanning path data, thereby completing the construction of the Neovius-Gyroid multi-level composite thermal insulation component.

[0007] In one alternative embodiment of the first aspect, the construction of the Neovius structure and the Gyroid structure respectively includes: constructing the Neovius structure using a three-period minimal surface implicit function.

[0008] The implicit function's left-hand side is the governing equation of the Neovius structure. The value of affects the relative density of the Neovius structure; and the Gyroid structure used for internal filling: The implicit function on the left side of the equation is the governing equation of the Gyroid structure, and L is the size of the lattice unit to ensure that the unit cell has the same period in the x, y, and z directions. The value of affects the relative density of the Gyroid structure.

[0009] In one alternative embodiment of the first aspect, based on the geometric features of the Neovius structure, geometric topology analysis is used to separate the solid regions of the Neovius structure, including one or more of body centers, face centers, edges, and vertices. This includes: deconstructing the solid regions of the Neovius structure into geometric features including body centers, face centers, edges, and vertices based on the geometric topology of the Neovius unit cell, and setting different geometric tool size parameters according to the spatial dimensions of different geometric features, wherein the geometric features are presented in an approximately spherical or hemispherical shape; using a sphere with a first preset radius as a Boolean operation tool to perform a Boolean intersection operation with the Neovius structure. ,in For the separated body-centered solid block, The Neovius framework is constructed using a sphere of a first preset radius; and a sphere of a second preset radius is used as a Boolean operation tool to perform the same Boolean intersection operation on the edge and vertex features respectively: ,in The separated edge solid blocks and corner solid blocks, The Neovius support skeleton structure, A sphere with a second preset radius.

[0010] In one alternative embodiment of the first aspect, a Boolean union operation is performed on the Neovius support skeleton structure and the Gyroid filler to generate a Neovius-Gyroid multi-level composite thermal insulation structure with interconnected pores, comprising:

[0011] Perform Boolean subtraction operations between the Neovius structure and the body center, edge, and corner solid blocks respectively: ,in The Neovius support skeleton structure, For the separated body-centered solid block, For the separated edge and corner solid blocks, a Neovius load-bearing skeleton structure is formed, and a cavity structure with the same shape as the target solid region is formed within it.

[0012] Perform Boolean intersection operations between the Gyroid structure and the solid blocks at the body center, edges, and vertices, respectively: ,in It is a Gyroid structure. For the separated body-centered solid block, For the separated edge and corner solid blocks, a Gyroid filler with the same spatial morphology as the cavity structure is generated; a Boolean union operation is performed on the Neovius support skeleton and the Gyroid filler to generate a Neovius-Gyroid multi-level composite thermal insulation structure with rigid external support provided by the Neovius support skeleton and internal Gyroid filler filling the cavity with interconnected pores; wherein, the Gyroid filler is at least partially located inside the body center, edge, or corner region of the Neovius support structure, and a continuous connection boundary is formed between the Gyroid filler and the Neovius support skeleton;

[0013] In one alternative embodiment of the first aspect, the Neovius-Gyroid multi-layer composite thermal insulation structure is sliced ​​to generate layer-by-layer scanning path data, including: importing the Neovius-Gyroid multi-layer composite thermal insulation structure into preset additive manufacturing software; optimizing the placement and adding supports to the Neovius-Gyroid multi-layer composite thermal insulation structure; slicing the Neovius-Gyroid multi-layer composite thermal insulation structure along the height direction; and generating two-dimensional scanning path data layer by layer based on the sliced ​​Neovius-Gyroid multi-layer composite thermal insulation structure.

[0014] In one alternative of the first aspect, when slicing the Neovius-Gyroid multi-layer composite thermal insulation structure along the height direction, the method includes: setting one or more scanning strategies among partitioned scanning, staggered scanning, or rotational scanning; and pre-adjusting the scanning energy density according to the local feature dimensions of the structure, wherein the pre-adjustment includes at least using a first energy density in the Neovius load-bearing skeleton structure region and a second energy density in the Gyroid filler and / or porous region.

[0015] In one alternative embodiment of the first aspect, when slicing the Neovius-Gyroid multi-layer composite thermal insulation structure, the method further includes: selecting a preset powder material, wherein the preset powder material is one or more of titanium alloy, high-temperature alloy, stainless steel or aluminum alloy powder; and controlling a vacuum drying device to dry the preset powder material at a first preset temperature for a preset time to remove the moisture adsorbed by the preset powder material, and cooling the preset powder material to a second preset temperature for later use after drying.

[0016] In one alternative embodiment of the first aspect, the use of a preset additive manufacturing process to achieve simultaneous forming of the Neovius load-bearing skeleton structure and the Gyroid filler within the same forming cycle based on the layer-by-layer scanning path data includes: laying the preset powder material in a layer-by-layer stacked manner to the forming area; performing energy beam scanning on the layer-by-layer stacked preset powder material within the same forming cycle based on the layer-by-layer scanning path data to achieve simultaneous forming of the Neovius load-bearing skeleton structure and the Gyroid filler; and cyclically laying the preset powder material and forming the structure until the construction of the Neovius-Gyroid multi-level composite thermal insulation component is completed.

[0017] In one alternative of the first aspect, after the construction of the Neovius-Gyroid multi-layer composite thermal insulation component is completed, the method includes: controlling a pre-set post-processing device to separate the Neovius-Gyroid multi-layer composite thermal insulation component from the substrate, wherein the pre-set post-processing process includes one or more of wire cutting or machining post-processing devices; and controlling a pre-set cleaning device to remove residual powder material within the Neovius-Gyroid multi-layer composite thermal insulation component, wherein the pre-set cleaning device includes one or more of high-pressure airflow, sandblasting, or ultrasonic vibration cleaning devices.

[0018] In a second aspect, this application provides a Neovius-Gyroid multi-level composite thermal insulation component prepared according to any one of the methods in the first aspect.

[0019] It should be understood that the above general description and the following detailed description are merely exemplary and do not limit this application. Attached Figure Description

[0020] The accompanying drawings, which are incorporated herein and form part of this specification, illustrate one or more embodiments of the present application and, together with the description, serve to explain the principles of the present application and to enable those skilled in the art to make and use the present application.

[0021] Figure 1 This is a schematic diagram of component connections for an exemplary additive manufacturing apparatus for a Neovius-Gyroid multi-level composite thermal insulation component according to some embodiments of this application.

[0022] Figure 2 This is a schematic flowchart of an exemplary additive manufacturing method for a Neovius-Gyroid multi-level composite thermal insulation component according to some embodiments of this application.

[0023] Figure 3This is a schematic diagram of an exemplary Neovius-Gyroid multi-level composite thermal insulation component according to some embodiments of this application; wherein, (a) is the overall structure and (b) is the internal cross-sectional structure.

[0024] Figure 4 This is a flowchart illustrating an exemplary method for separating entity regions of a Neovius structure according to some embodiments of this application.

[0025] Figure 5 This is a schematic flowchart illustrating an exemplary method for constructing a Neovius-Gyroid multi-level composite thermal insulation structure according to some embodiments of this application.

[0026] Figure 6 This is a schematic flowchart of an exemplary structural slicing processing method according to some embodiments of this application.

[0027] Figure 7 This is a schematic flowchart of an exemplary structural additive manufacturing method according to some embodiments of this application.

[0028] Figure 8 This is a schematic flowchart of an exemplary post-processing method for a structure according to some embodiments of this application.

[0029] Figure 9 This is an exemplary additive manufacturing process and physical schematic diagram according to some embodiments of this application; wherein, (a) is a printing process diagram, (b) is a sample diagram after forming, (c) is a physical diagram after cleaning treatment, (d) is a physical diagram after sandblasting treatment, and (e) is a physical diagram after electrochemical treatment.

[0030] Figure 10 This is an exemplary steady-state thermal simulation result diagram according to some embodiments of this application; wherein, (a) is the steady-state thermal simulation result of a single Neovius structure, and (b) is the steady-state thermal simulation result of a Neovius-Gyroid multi-level composite thermal insulation structure.

[0031] Figure 11 This is a schematic diagram of an exemplary compression experiment result according to some embodiments of this application; wherein, (a) is the compression process of the Neovius-Gyroid multi-level composite thermal insulation structure, and (b) is the compression force-displacement curve of Neovius with different cell sizes.

[0032] Figure 12 This is a schematic diagram of the module connection of an exemplary control unit according to some embodiments of this application.

[0033] Figure 13 This is a schematic diagram of the structure of an exemplary electronic device according to some embodiments of this application. Detailed Implementation

[0034] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. However, these exemplary embodiments may be implemented in various forms and should not be construed as limited to the examples set forth herein; rather, the description of these embodiments is intended to make this application more comprehensive and complete, and to fully convey the concept of the exemplary embodiments to those skilled in the art. The described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Numerous specific details are provided in the following description to provide a deeper understanding of embodiments of this application.

[0035] To facilitate understanding of the technical solutions provided in this application, the relevant terms are explained below.

[0036] It should be noted that the terminology used in the implementation section of this application is only for explaining the embodiments of this application and is not intended to limit this application.

[0037] For example, the term "and / or" in this article simply describes the relationship between related objects, indicating that three relationships can exist. For instance, A and / or B can represent: A alone, A and B simultaneously, and B alone. The term "at least one" simply describes the combination relationship of listed objects, indicating that one or more can exist. For instance, at least one of the following: A, B, C can represent the following combinations: A alone, B alone, C alone, A and B simultaneously, A and C simultaneously, B and C simultaneously, and A, B, and C simultaneously. The term "multiple" refers to two or more. The character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0038] For example, the term "correspondence" can indicate a direct or indirect correspondence between two things, or an association between them, or a relationship of instruction and being instructed, configuration and being configured, etc. The term "instruction" can be direct, indirect, or indicate an association. For example, A instructing B can mean A directly instructs B, for example, B can be obtained through A; it can also mean A indirectly instructs B, for example, A instructs C, B can be obtained through C; or it can mean an association between A and B. The terms "predefined" or "preconfigured" can refer to pre-stored codes, tables, or other relevant information that can be used for instruction in the device, or it can refer to something agreed upon by a protocol. "Protocol" can refer to standard protocols in the field. The term "when..." can be interpreted as "if," "when," or "in response," etc. Similarly, depending on the context, the phrases "if determined" or "if detected (the condition or event of the statement)" can be interpreted as "when determined" or "in response to determined" or "when detected (the condition or event of the statement)" or "in response to detected (the condition or event of the statement)" and similar descriptions. The terms "first," "second," "third," "fourth," "A," "B," etc., are used to distinguish different objects, not to describe a specific order. The terms "includes" and "has," and any variations thereof, are intended to cover non-exclusive inclusion.

[0039] TPMS (Triply Periodic Minimal Surface) is a surface that is periodic in three independent directions in three-dimensional space and has an average curvature of zero. In the field of engineering, TPMS has advantages such as full continuity, smooth transition, high specific strength and high porosity.

[0040] The Neovius structure is a topological configuration in TPMS, characterized by high node connectivity and stronger spatial rigidity. In this application, the Neovius structure is used as a load-bearing skeleton to ensure the overall rigidity of the components by utilizing its excellent mechanical support capabilities.

[0041] The Gyroid structure is also a topological configuration in TPMS. It is a topological configuration without rotational symmetry and mirror symmetry, and has complex spiral interconnected channels inside. In this application, it is used as a thermal insulation unit to extend the heat conduction path by utilizing its extremely high spatial tortuosity, thereby significantly reducing thermal conductivity.

[0042] The thermal bridge effect refers to the tendency of heat to be transferred quickly through the path of least thermal resistance (usually a highly dense metal structure). This application achieves excellent thermal insulation by implanting a Gyroid structure to interrupt or extend the original direct thermal bridge path of the Neovius structure.

[0043] Figure 1 This is a schematic diagram of an exemplary additive manufacturing apparatus for a Neovius-Gyroid multi-level composite thermal insulation component, according to some embodiments of this application.

[0044] refer to Figure 1 As shown, the additive manufacturing apparatus 100 for Neovius-Gyroid multi-layer composite thermal insulation components of this application includes at least an additive manufacturing device 101, a terminal device 102, and a control unit 103. The components are connected by wired or wireless means to form the additive manufacturing apparatus 100 for manufacturing Neovius-Gyroid multi-layer composite thermal insulation components.

[0045] When in use, the additive manufacturing equipment 101 can be set according to the preset additive manufacturing process requirements, which include, but are not limited to, laser powder bed melting (LPBF), electron beam melting (EBM), selective laser sintering (SLS), selective laser melting (SLM), etc.; the additive manufacturing equipment 101 includes at least a forming chamber, a base for providing structural forming, a powder laying mechanism for powder laying, an energy beam loading unit for applying energy to the material to achieve melting or solidification, a motion control mechanism for controlling the scanning path and interlayer movement, and an environmental control module for regulating the atmosphere, temperature and pressure in the forming chamber, etc.

[0046] In some examples of this application, in different implementation processes, the additive manufacturing equipment 101 can select the corresponding energy source and forming method according to the material. For example, it can use laser or electron beam melting for metal materials, selective laser sintering for polymer materials, and laser sintering for ceramics or composite materials.

[0047] The terminal device 102 is used to send parameter commands to the additive manufacturing equipment 101 and the control unit 103 and to receive real-time data transmitted by the additive manufacturing equipment 101 and the control unit 103, as well as to perform slicing processing using additive manufacturing slicing software. It can be one or more of the following: smartphone, host computer, industrial control computer, tablet computer, laptop computer or terminal device with data processing capabilities.

[0048] Specifically, the main functions of the terminal device 102 include importing three-dimensional model files of Neovius-Gyroid multi-level composite thermal insulation components, such as STL, 3MF, or voxel data based on implicit functions; using preset additive manufacturing slicing software to perform layer-by-layer slicing of the model to generate layer-by-layer scanning path data; setting additive manufacturing process parameters including layer thickness, scanning speed, power density, and filling strategy; sending task instructions to the control unit 103; and displaying the current manufacturing progress, equipment operating status, and alarm information.

[0049] The control unit 103 is connected to the additive manufacturing equipment 101 and the terminal equipment 102 respectively. It is used to receive the instructions issued by the terminal equipment 102, parse the instructions and send them to the corresponding additive manufacturing equipment 101, thereby executing each step in the additive manufacturing method of Neovius-Gyroid multi-level composite thermal insulation component.

[0050] In some embodiments of this application, the additive manufacturing apparatus 100 further includes a vacuum drying device 104, a post-processing device 105, and a cleaning device 106, which are connected to the control unit 103 via wired or wireless means and operate under the scheduling of the control unit 103.

[0051] Specifically, the vacuum drying equipment 104 is used to dehumidify powder materials by applying a first preset temperature to the powder materials in a vacuum or low-oxygen environment and maintaining it for a preset time to remove moisture and volatile impurities adsorbed on the surface of the powder particles. The first preset temperature is set according to the type of powder material, for example, 120°C. The preset time is adjusted according to the powder particle size and moisture content, for example, 2 hours. After drying, the powder materials are preferably cooled to a safe operating temperature, for example, room temperature.

[0052] The post-processing equipment 105 is used to separate the additively manufactured structure from the substrate by wire cutting, machining, or a combination thereof; wherein, in this application, wire cutting is preferred to achieve non-destructive separation of the structure from the substrate, with a smaller heat-affected zone, which can avoid additional mechanical stress or thermal damage to the structure.

[0053] The cleaning equipment 106 is used to remove residual powder material from the surface and interior of the formed structure by means of high-pressure airflow cleaning, sandblasting, ultrasonic vibration or a combination thereof.

[0054] Specifically, the vacuum drying equipment 104, the post-processing equipment 105, and the cleaning equipment 106 all adopt existing equipment in the field. Their connection methods, operation control methods, and function implementation methods can all be implemented by those skilled in the art based on existing industrial control technology. The control unit 103 can be implemented using a PLC control system, an industrial computer, or an embedded control system.

[0055] Some embodiments of this application provide an additive manufacturing method for a Neovius-Gyroid multi-level composite thermal insulation component, which can additively manufacture a Neovius-Gyroid multi-level composite thermal insulation component based on the fusion of Neovius and Gyroid structures; wherein, the Neovius structure is used for a high-stiffness load-bearing configuration, and the Gyroid structure is used for a thermal insulation configuration.

[0056] Figure 2 A schematic flowchart of an exemplary additive manufacturing method for a Neovius-Gyroid multi-level composite thermal insulation component, according to some embodiments of this application, is shown. Figure 3 This application shows a schematic diagram of the structure of an exemplary Neovius-Gyroid multi-level composite thermal insulation component according to some embodiments, wherein... Figure 3 (a) is the overall structure. Figure 3 (b) shows the internal cross-sectional structure. The additive manufacturing method 200 can be interactively executed by the additive manufacturing equipment 101, the terminal device 102, and the control unit 103. The terminal device 102 can be one or more of a smartphone, desktop computer, tablet computer, and laptop computer.

[0057] refer to Figure 2 and Figure 3 As shown. The additive manufacturing method 200 includes at least the steps 201 to 204.

[0058] 201: Construct Neovius and Gyroid structures respectively, and based on the geometric characteristics of the Neovius structure, use geometric topology analysis to separate the solid regions of the Neovius structure, including the body center, face center, edges, and vertices.

[0059] The Neovius structure is a topological configuration of the Triply Periodic Minimal Surface (TPMS) structure. Its surfaces are periodically repeated along the X, Y, and Z directions in three-dimensional space, with an overall average curvature approaching zero and composed of continuous smooth surfaces. It possesses advantages such as uniform stress distribution, low local stress concentration, high specific stiffness, and strong load-bearing capacity. The Gyroid structure is another topological configuration of the Triply Periodic Minimal Surface structure. Its geometric characteristics include the absence of straight lines, the absence of mirror symmetry, fully continuous surfaces, and three-dimensional spiral interconnected channels. It also boasts advantages such as excellent thermal insulation performance, good isotropy, and superior fluid dynamics.

[0060] refer to Figure 3 As shown. Specifically, in step 201, the Neovius structure and the Gyroid structure are constructed respectively, including at least the following steps 201a to 201b.

[0061] 201a: Parametric modeling is performed using implicit functions of a three-period minimal surface as the basis for topological modeling, constructing a Neovius structure: The implicit function on the left side of the equation is the governing equation of the Neovius structure, and L is the size of the lattice unit to ensure that the unit cell has the same period in the x, y, and z directions. The preferred value of L is 5 mm to 15 mm. The value of affects the relative density of the Neovius structure; the wall thickness, porosity and solid proportion of the Neovius structure are controlled by adjusting the isosurface threshold and midsurface offset parameter.

[0062] In some examples of this application, a Neovius structure of macroscopic load-bearing skeleton is created in Ntopology software, with the overall size set to 30×30×30mm, the unit size to 15×15×15mm, and the midsurface offset value set to -0.01, so as to form a load-bearing skeleton network with continuous closed surfaces.

[0063] 201b: Creating a Gyroid structure for internal padding using implicit functions: The implicit function on the left side of the equation is the governing equation of the Gyroid structure, and L is the size of the lattice unit to ensure that the unit cell has the same period in the x, y, and z directions. The preferred value of L is 5 mm to 15 mm. The value of affects the relative density of the Gyroid structure.

[0064] In some examples of this application, L=10 is set, and two different c values ​​(C1=0.5, C2=-0.5) are selected to generate the first Gyroid entity structure and the second Gyroid entity structure respectively. Then, Boolean subtraction operation is performed on the first Gyroid entity structure and the second Gyroid entity structure to obtain a Gyroid basic structure with continuous connected pores.

[0065] 202: Perform Boolean subtraction and Boolean intersection operations on the solid region with the Neovius structure and the Gyroid structure respectively to construct a Neovius support skeleton structure with a continuous curved surface and form a cavity in the Neovius support skeleton structure, and simultaneously generate a Gyroid infill body with the same shape.

[0066] Specifically, Boolean subtraction can remove local high solid content areas in the Neovius structure to form an internal thermally insulated cavity; Boolean intersection can simultaneously extract Gyroid fillers with the same spatial shape as the cavity, thereby ensuring that the Gyroid fillers can achieve spatial matching and continuous connection with the Neovius support frame.

[0067] Figure 4 A flowchart illustrating an exemplary Neovius structure entity region separation method according to some embodiments of this application is shown.

[0068] refer to Figure 4 As shown. Specifically, in step 202, based on the geometric characteristics of the Neovius structure, geometric topology analysis is used to separate the solid regions of the Neovius structure, including one or more of the body center, face center, edges, and vertices, including at least the following steps 202a to 202c.

[0069] 202a: Based on the geometric topology of the Neovius unit cell, the solid region of the Neovius structure is deconstructed into geometric features including body center, face center, edges and vertices, and different geometric tool size parameters are set according to the spatial dimensions of different geometric features, wherein the geometric features are presented in an approximately spherical or hemispherical shape.

[0070] Specifically, by performing local curvature analysis, solid thickness analysis, and node connectivity analysis on the Neovius structure, high solid aggregation regions in the Neovius structure are identified. The solid region located at the center of the unit cell is defined as the body-centered region, the region connected at the center of the curved surface is defined as the face-centered region, the region connected at the edge of the unit cell is defined as the edge region, and the region located at the intersection of multiple curved surfaces is defined as the vertex region. Then, based on the body-centered, face-centered, edge, and vertex regions, the Neovius structure is deconstructed into body-centered features, face-centered features, edge features, and vertex features. A larger geometric tool is set for the body-centered region, while a smaller geometric tool is used for the edge and vertex regions.

[0071] 202b: Using a sphere with a first preset radius as a Boolean operation tool, perform Boolean intersection operations with the Neovius structure: ,in For the separated body-centered solid block, The Neovius support skeleton structure is a sphere with a first preset radius.

[0072] Specifically, a spherical geometry tool is established at the center of the Neovius unit cell, and a Boolean intersection operation is performed between the sphere and the Neovius structure to extract the body-centered solid block from the inside of the Neovius structure. The first preset radius ranges from 2 mm to 6 mm. In this application, the first preset radius is set to be less than 1 / 2 of the size of the Neovius unit cell to avoid spatial interference between adjacent units. The reference sphere radius is 8 mm.

[0073] 202c: Using a sphere with a second preset radius as the Boolean operation tool, perform the same Boolean intersection operation on the edge and vertex features respectively: ,in The separated edge solid blocks and corner solid blocks, The Neovius support skeleton structure, A sphere with a second preset radius.

[0074] Specifically, multiple second spheres are established at the connection positions of each edge and apex feature of the Neovius structure, and Boolean intersection operations are performed with the Neovius structure respectively to extract the solid connection regions of the edges and apex in the Neovius structure; the second preset radius is smaller than the first preset radius, and the smaller sphere size ensures that the necessary load-bearing connection paths are still retained after the edges and apex are partially replaced. In this application, the sphere radius is set to 5.5mm.

[0075] 203: Perform a Boolean union operation on the Neovius support skeleton structure and the Gyroid filler to generate a Neovius-Gyroid multi-level composite thermal insulation structure with interconnected pores.

[0076] By performing a Boolean union operation on the Neovius load-bearing skeleton structure and the Gyroid infill, the two structures can form a continuous curved surface connection in space, avoiding interface fractures, sharp angle transitions, and discontinuous connection areas that exist in traditional prefabricated structures, and improving the load transfer capacity and thermal protection performance of the overall structure.

[0077] Figure 5 The diagram illustrates a flowchart of an exemplary method for constructing a Neovius-Gyroid multi-level composite thermal insulation structure according to some embodiments of this application.

[0078] refer to Figure 5 As shown. Specifically, in step 203, a Boolean union operation is performed on the Neovius support skeleton structure and the Gyroid filler to generate a Neovius-Gyroid multi-level composite thermal insulation structure with interconnected pores, including at least the following steps 203a to 203c.

[0079] 203a: Perform Boolean subtraction operations between the Neovius structure and the body center, edge, and corner solid blocks respectively: ,in The Neovius support skeleton structure, For the separated body-centered solid block, The separated edge and corner solid blocks form the Neovius support skeleton structure, and a cavity structure with the same shape as the target solid region is formed within it.

[0080] Specifically, the body-centered solid block, edge solid block, and apex solid block extracted in step 202 are respectively regarded as local subtractive regions. Boolean subtraction is performed with the Neovius structure to form a local cavity inside the Neovius structure that is consistent with the spatial shape of the target solid region. The boundary of the formed cavity still maintains the continuous surface characteristics of TPMS, thereby avoiding the local stress concentration caused by traditional acute-angle cavities. Furthermore, a continuous curvature transition relationship is formed between the cavity boundary and the main body of the Neovius structure.

[0081] 203b: Perform Boolean intersection operations between the Gyroid structure and the body center, edge, and corner solid blocks respectively: ,in It is a Gyroid structure. For the separated body-centered solid block, For the separated edge and corner solid blocks, a Gyroid filler body is generated that matches the spatial morphology of the cavity structure.

[0082] Specifically, the body-centered solid block, edge solid block, and apex solid block are respectively used as spatial constraint regions of the Gyroid structure and Boolean intersection operations are performed with the Gyroid structure to generate Gyroid local fillers that are consistent with the spatial morphology of the Neovius cavity structure. The Gyroid fillers are located at least partially inside the body-centered region, edge region, or apex region of the Neovius supporting skeleton structure. The outer boundary of the Gyroid fillers matches the boundary of the Neovius cavity to ensure the spatial nesting correspondence between the two.

[0083] After generating the Gyroid infill, to avoid isolated thin walls, broken channels, or non-connected structures in local areas, one or more of the following methods are used to perform continuous correction processing on the Gyroid infill: local wall thickness smoothing, channel connectivity optimization, curvature continuity optimization, and implicit function smoothing transition processing. This results in a continuous transition interface between the Gyroid infill and the Neovius support skeleton. The local wall thickness, porosity, and radius of curvature of the continuous transition interface change continuously along the spatial direction.

[0084] 203c: Perform a Boolean union operation on the Neovius support skeleton and the Gyroid filler to generate a Neovius-Gyroid multi-level composite thermal insulation structure with rigid external support provided by the Neovius support skeleton and internal Gyroid filler filling the cavity with interconnected pores.

[0085] Specifically, the Neovius load-bearing skeleton structure and the Gyroid filler, after forming the cavity, are imported into a unified implicit modeling environment and Boolean union operation is performed to achieve the fusion of the Neovius load-bearing skeleton structure and the Gyroid filler. The fused Neovius-Gyroid multi-level composite thermal insulation structure includes an external rigid load-bearing frame formed by the Neovius load-bearing skeleton structure and a Gyroid filler filled in the internal cavity of the Neovius. The Neovius load-bearing skeleton structure and the Gyroid filler are spatially connected and together form a continuous interconnected pore network. This interconnected pore network forms continuous flow paths in the X, Y, and Z directions.

[0086] Specifically, the outer region of the Neovius-Gyroid multi-level composite thermal insulation structure is formed by a Neovius load-bearing skeleton structure to form a rigid support frame, while the internal cavity is filled with Gyroid filler. The Neovius load-bearing skeleton structure and the Gyroid filler are spatially continuous and form a connected pore network. This can effectively reduce the equivalent thermal conductivity of the structure while ensuring the overall mechanical properties, and achieve synergistic optimization of load-bearing performance and thermal insulation performance. At the same time, since the filler adopts a Gyroid structure, it is not only beneficial for thermal insulation, but also facilitates the cleaning of powder materials after molding.

[0087] In some examples of this application, when generating the Neovius-Gyroid multi-level composite thermal insulation structure, in the spatial overlapping or adjacent areas of the Neovius load-bearing skeleton structure and the Gyroid filler, local smooth interpolation is performed through continuous function mapping to form a continuous material transition zone, so that the structural wall thickness, porosity and radius of curvature change smoothly along the spatial direction.

[0088] Specifically, the continuous function mapping includes one or more of the following: threshold interpolation based on spatial distance field, wall thickness smoothing based on weight function, or structural smoothing based on curvature constraints, which are specifically set by the designer according to actual needs and costs.

[0089] For example, the Boolean operations of this application can be performed by parametric modeling software, such as Ntopology, Rhino and Grasshopper, Materialise3-matic, or software platforms with implicit modeling capabilities.

[0090] After the Neovius-Gyroid multi-level composite thermal insulation structure is generated, designers can use relevant parametric modeling software to perform one or more of the following: mesh smoothing, removal of sharp corners and thin-walled abnormal areas, repair of non-manifold topology, or control of minimum feature size to meet additive manufacturing process requirements. The specific settings are determined by the designer based on actual needs and cost. Then, the Neovius-Gyroid multi-level composite thermal insulation structure is exported as one or more of the following: STL file, 3MF file, or voxel data file based on implicit functions.

[0091] 204: The Neovius-Gyroid multi-level composite thermal insulation structure is sliced, and layer-by-layer scanning path data is generated through slicing and path planning. A preset additive manufacturing process is adopted, and the Neovius load-bearing skeleton structure and Gyroid filler are synchronously formed in the same forming cycle according to the layer-by-layer scanning path data, thereby completing the construction of the Neovius-Gyroid multi-level composite thermal insulation component and avoiding interface defects caused by separate manufacturing.

[0092] The preset additive manufacturing process includes, but is not limited to, laser powder bed melting, electron beam melting, selective laser sintering of polymers, selective laser melting, or other high-energy beam powder bed additive manufacturing processes. The specific process is set by the designer based on the actual additive manufacturing equipment and requirements.

[0093] Figure 6 A flowchart illustrating an exemplary structural slicing method according to some embodiments of this application is shown.

[0094] refer to Figure 6 As shown, specifically, in step 204, the Neovius-Gyroid multi-level composite thermal insulation structure is sliced ​​to generate layer-by-layer scanning path data, including at least the following steps 204a to 204d.

[0095] 204a: Import the Neovius-Gyroid multi-level composite thermal insulation structure into the preset additive processing software in the above-mentioned three-dimensional digital model format, such as STL file, 3MF file, or voxel data file format based on implicit functions.

[0096] The preset additive processing software uses slicing software corresponding to the relevant additive manufacturing process, such as Ntopology, Magics, Netfabb, or a software platform with slicing and path planning functions.

[0097] 204b: Optimize the placement and add supports to the Neovius-Gyroid multi-level composite thermal insulation structure.

[0098] The optimized placement of the supports includes one or more strategies such as determining the optimal forming direction, reducing the proportion of overhanging areas, reducing the volume of support structures, and optimizing the direction of thermal stress release. This ensures that the main load-bearing direction of the Neovius load-bearing skeleton structure aligns with the forming direction, thereby improving structural mechanical continuity and reducing the risk of interlayer defects. When adding supports, support structures are added based on the local geometric features of the structure, including one or more of point supports, line supports, or surface supports. Preferably, supports are added only to the outer contour area of ​​the Neovius load-bearing skeleton structure. This serves to fix overhanging areas, suppress thermal deformation, improve heat dissipation paths, prevent printing collapse, and improve surface quality.

[0099] 204c: The Neovius-Gyroid multi-layer composite thermal insulation structure is sliced ​​along the forming height direction to generate two-dimensional layer geometric data.

[0100] Specifically, in step 204c, the Neovius-Gyroid multi-level composite thermal insulation structure is sliced ​​along the forming height direction, including: setting one or more scanning strategies among partitioned scanning, staggered scanning, or rotational scanning; and preset adjusting the scanning energy density according to the local feature size of the structure, wherein the preset adjustment includes at least using a first energy density in the Neovius load-bearing skeleton structure region and a second energy density in the Gyroid filler and / or porous region, and the first energy density is greater than the second energy density, so that the Neovius load-bearing skeleton structure region obtains higher density and metallurgical bonding quality, while the Gyroid filler region avoids over-melting leading to pore closure or thin-wall collapse.

[0101] In some examples of this application, different scanning methods can be used for the Neovius support skeleton structure and the Gyroid infill region. For example, contour-first scanning can be used for the Neovius support skeleton structure region, while interleaved filling scanning can be used for the Gyroid infill region.

[0102] In some examples of this application, when making preset adjustments, the energy density can be reduced in porous or fine feature regions to avoid overmelting, and the energy density can be increased in high load regions to enhance density.

[0103] 204d: Based on the two-dimensional layer geometry data of the sliced ​​Neovius-Gyroid multi-level composite thermal insulation structure, two-dimensional scanning path data is generated layer by layer.

[0104] The two-dimensional scanning path data includes, but is not limited to, scanning trajectory, scanning sequence, energy beam power distribution, scanning speed, and energy input parameters, which are used to control the additive manufacturing equipment to perform the layer-by-layer powder spreading and layer-by-layer melting process.

[0105] In some embodiments of this application, in step 204, when slicing the Neovius-Gyroid multi-layer composite thermal insulation structure, the method further includes: selecting a preset powder material, wherein the preset powder material includes one or more of titanium alloy, high-temperature alloy, stainless steel or aluminum alloy powder; after the preset powder material is selected, the designer manually or by operating equipment introduces the preset powder material into a vacuum drying device, and then controls the vacuum drying device to dry the preset powder material at a first preset temperature for a preset time, thereby removing the moisture adsorbed by the preset powder material, and after drying, the preset powder material is cooled to a second preset temperature for later use.

[0106] The first preset temperature is set by the designer according to the type of powder material, for example, 80°C to 150°C, and 120°C is used in this application as an example; the preset time is adjusted by the designer according to the powder particle size and moisture content, for example, 1 hour to 12 hours, and 2 hours is used in this application as an example; the second preset temperature is preferably cooled to a safe operating temperature, for example, 15°C to 40°C, and room temperature is used in this application as an example; thus, by drying the material, the moisture adsorbed by the powder material can be removed, the risk of porosity defects during the forming process can be reduced, unstable splashing in the molten pool can be avoided, and the melt density of the material can be improved.

[0107] Figure 7 A schematic flowchart of an exemplary structural additive manufacturing method according to some embodiments of this application is shown; Figure 9 The illustration shows an exemplary additive manufacturing process and physical schematic diagram of some embodiments of this application, wherein, Figure 9 (a) is a diagram of the printing process. Figure 9 (b) is a sample image after molding is completed. Figure 9 (c) is a picture of the actual product after cleaning. Figure 9 (d) is a picture of the actual object after sandblasting. Figure 9 (e) is a photograph of the actual object after electrochemical treatment.

[0108] refer to Figure 7 and Figure 9 As shown. Specifically, in step 204, a preset additive manufacturing process is used to simultaneously form the Neovius load-bearing skeleton structure and the Gyroid filler within the same forming cycle according to the layer-by-layer scanning path data, thereby completing the construction of the Neovius-Gyroid multi-level composite thermal insulation component, including at least the following steps 204e to 204h.

[0109] 204e: The powder feeding mechanism of the preset additive manufacturing equipment receives the preset powder material after drying and imports the layer-by-layer scanning path data into the terminal equipment.

[0110] 204f: The powder spreading mechanism of the additive manufacturing equipment lays the preset powder material conveyed by the powder supply mechanism into the forming area in a layer-by-layer stacking manner to form a uniform powder layer; wherein, for the Neovius support skeleton structure area and the Gyroid filler area, the layer thickness is preferably matched with the minimum structural feature size to improve the forming accuracy of complex curved surface structures.

[0111] 204g: Based on the layer-by-layer scanning path data, an energy beam scan is performed on the surface of the uniform powder layer within the same forming cycle, causing the preset powder material to locally melt and solidify, thereby achieving the synchronous forming of the Neovius support skeleton structure and the Gyroid filler; wherein, the energy beam is determined by the type of preset additive manufacturing equipment, including a laser beam, an electron beam, or other high-energy beam sources; during the scanning process, different process parameters are called according to the partitions of the Neovius support skeleton structure and the Gyroid filler.

[0112] Specifically, synchronous forming refers to the melting and solidification of the Neovius support skeleton structure and the Gyroid filler within the same processing layer, and the Neovius support skeleton structure and the Gyroid filler form an integral structure through continuous material metallurgical bonding, which does not require subsequent assembly or secondary connection.

[0113] 204h: Cycle through the preset powder material laying and structural forming of 204f and 204g until the construction of the Neovius-Gyroid multi-level composite thermal insulation component is completed.

[0114] In this process, after each layer scan is completed, the thickness is reduced by one layer and the powder layup is repeated, followed by repeated energy scans. This cycle is repeated until all layers are constructed, ultimately completing the construction of the Neovius-Gyroid multi-layer composite thermal insulation component.

[0115] Figure 8 A flowchart illustrating an exemplary post-processing method for structures according to some embodiments of this application is shown.

[0116] refer to Figure 8 and Figure 9 As shown. In some embodiments of this application, in step 204, after the construction of the Neovius-Gyroid multi-layer composite thermal insulation component is completed, the additive manufacturing method 200 of this application further includes the following steps 204i to 204j.

[0117] 204i: Controlling a pre-processing device to separate the Neovius-Gyroid multi-layer composite thermal insulation component from the substrate, wherein the pre-processing process includes one or more of wire cutting or machining equipment.

[0118] Specifically, by separating the structure from the substrate, the connecting support structure formed during the manufacturing process can be removed, thereby decoupling the component from the forming platform and preventing residual stress concentration in the structure.

[0119] For example, this application uses wire electrical discharge machining (EDM) with a cutting speed of 0.5–3 mm / min and a circulating cooling medium to separate the Neovius-Gyroid multilayer composite thermal insulation component from the substrate; and controls the wire electrical discharge machining force to be less than the allowable deformation threshold of the thin-walled area of ​​the Neovius-Gyroid multilayer composite thermal insulation component.

[0120] 204j: After the structure is separated from the substrate, a preset cleaning device is used to remove residual powder material in the Neovius-Gyroid multi-level composite thermal insulation component, wherein the preset cleaning device includes one or more of high-pressure airflow, sandblasting or ultrasonic vibration cleaning devices.

[0121] Specifically, when high-pressure airflow is used for cleaning, high-speed airflow enters the interconnected pore network of the Neovius-Gyroid multi-level composite thermal insulation component to achieve internal powder discharge; when sandblasting is used for cleaning, unmelted powder adhering to the surface of the Neovius-Gyroid multi-level composite thermal insulation component is removed; when ultrasonic vibration is used for cleaning, the adhesion between powder particles is reduced.

[0122] Therefore, this application introduces a dual-lattice topological nesting design, using a highly connected and rigid Neovius structure as a continuous macroscopic Neovius load-bearing skeleton. Through geometric topological analysis of the Neovius unit cell, the Gyroid structure is precisely implanted into thermally weak areas such as the body center, edges, and apex, forming a topological configuration of the main load-bearing skeleton combined with distributed thermal insulation units. Unlike traditional simple nesting, this application retains the complete mechanical load-bearing path of Neovius while significantly increasing the heat flow resistance by utilizing the tortuous heat conduction path of the Gyroid, thus solving the contradiction between mechanical performance and thermal insulation performance from the design source.

[0123] Furthermore, this application employs laser selective melting technology to achieve integrated manufacturing of multi-level TPMS composite structures without any mechanical connection parts, fundamentally eliminating the thermal bridging effect and non-functional weight introduced by mechanical connectors in traditional assembled structures; the external Neovius load-bearing skeleton structure and the internal Gyroid filler solidify synchronously in the same processing layer and form a dense metallurgical bond, ensuring the mechanical continuity and integrity of the structure, and improving the overall thermal protection efficiency and lightweight level.

[0124] Furthermore, this application employs a regional differential scanning energy density matching strategy based on structural topological features, setting different energy input parameters in the Neovius support skeleton structure region and the Gyroid filler region respectively, so that the thick-walled region achieves a highly dense metallurgical bond, and the thin-walled or highly porous region avoids over-melting collapse, thereby improving the forming accuracy of complex curved surface structures.

[0125] In some embodiments of this application, when generating a Neovius-Gyroid multi-layer composite thermal insulation component with a skeleton and core layer co-configuration, a powder material retention area can be designed in the Gyroid filler to seal a portion of the powder material as a damping, energy absorption, or thermal insulation medium; the specific number, location, and size of the sealed pore areas, as well as the powder material retention ratio, and other parameters are set by the designer according to actual needs.

[0126] The preferred embodiments of this application have been described in detail above with reference to the accompanying drawings. However, this application is not limited to the specific details of the embodiments described above. Within the scope of the technical concept of this application, various simple modifications can be made to the technical solutions of this application, and these simple modifications all fall within the protection scope of this application. For example, the various specific technical features described in the specific embodiments described above can be combined in any suitable manner without contradiction. To avoid unnecessary repetition, this application will not describe the various possible combinations separately. Furthermore, various different embodiments of this application can also be arbitrarily combined, as long as they do not violate the spirit of this application, they should also be considered as the content disclosed in this application.

[0127] It should also be understood that, in the various method embodiments of this application, the order of the processes mentioned above does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.

[0128] Figure 10 A schematic diagram illustrating an exemplary steady-state thermal simulation result of some embodiments of this application is shown, wherein, Figure 10 (a) shows the steady-state thermal simulation results of a single Neovius structure. Figure 10 (b) shows the steady-state thermal simulation results of the Neovius-Gyroid multi-level composite thermal insulation structure; Figure 11 A schematic diagram illustrating exemplary compression experiment results of some embodiments of this application is shown, wherein, Figure 11 (a) shows the compression process of the Neovius-Gyroid multi-level composite thermal insulation structure. Figure 11 (b) shows the compressive force-displacement curves for Neovius at different cell sizes.

[0129] To verify the thermal insulation advantages of the Neovius-Gyroid multi-level composite thermal insulation component of this application, a comparative simulation of single and composite configurations with the same external dimensions was conducted using the finite element analysis method; through Figure 10 and Figure 11The comparative data shows that the Neovius-Gyroid multi-level composite thermal insulation component described in this application has successfully achieved a synergistic gain of high stiffness load-bearing capacity (guaranteed by the Neovius skeleton) and low equivalent thermal conductivity (achieved by the Gyroid filler) without significantly increasing the weight, thus solving the technical problem of force and heat imbalance in traditional sandwich structures or single TPMS structures.

[0130] refer to Figure 10 As shown, specifically, Figure 10 (a) shows the steady-state thermal simulation results of a single Neovius structure. Under the same bottom heating boundary conditions, due to the continuous and relatively direct conduction path of the Neovius structure, the heat flow can penetrate the structure quickly, resulting in an average temperature of 192.3°C at the top. This indicates that although a single high-stiffness structure has strong load-bearing capacity, its thermal bridging effect is significant and its thermal insulation efficiency is limited. Figure 10 (b) shows the steady-state thermal simulation results of the Neovius-Gyroid multi-level composite thermal insulation component. While keeping the external Neovius load-bearing skeleton unchanged, by nesting Gyroid fillers in key parts such as the body center and edges, the average temperature at the top is reduced to 148.4°C, which is significantly lower than that of a single structure. Thus, the simulation results prove that the Gyroid filler, with its complex spiral spatial characteristics, extends the conduction path of phonons / heat flow (i.e., increases the tortuosity factor), effectively weakening the thermal bridging effect of the macroscopic skeleton. This supports the advantages of the main load-bearing skeleton combined with the distributed thermal insulation unit configuration in thermal management in this application from the perspective of experimental data.

[0131] refer to Figure 11 As shown, specifically, Figure 11 (a) shows the compression test process of Neovius-Gyroid multi-level composite thermal insulation component prepared by L-PBF process on a universal testing machine. The experiment observed that the component exhibited a stable deformation mode during compression. Due to the formation of a dense metallurgical bond between the outer Neovius skeleton and the inner Gyroid filler, the structure did not show obvious interface peeling or delamination failure when subjected to huge loads. Figure 11 Figure (b) shows the compressive force-displacement curves of the Neovius structure at different cell sizes (7.5 mm, 10 mm, 15 mm). The results show that as the lattice unit size (L) decreases (e.g. from 15 mm to 7.5 mm), the load-bearing capacity (N) of the structure at the same displacement increases significantly. The 7.5 mm group (blue curve) exhibits the highest initial stiffness and peak load, making it suitable for extremely high-strength load-bearing environments. The 15 mm group (black curve) and the 10 mm group (red curve) exhibit wider plateau regions, which are beneficial for energy absorption.

[0132] The experimental results further confirm the aforementioned technical features of this application, namely, that designers can achieve targeted optimization and customized matching of structural mechanical properties (such as specific strength and specific stiffness) by flexibly adjusting the cell size parameters and isosurface thresholds of Neovius or Gyroid according to actual service requirements.

[0133] thus, Figure 12 A schematic diagram of the module connection of an exemplary control unit according to some embodiments of this application is shown.

[0134] refer to Figure 12 As shown. The control unit 103 may include: a structure construction module 103a, used to construct a Neovius structure and a Gyroid structure respectively, and to separate the solid regions of the Neovius structure, including the body center, face center, edges, and vertices, based on the geometric characteristics of the Neovius structure using geometric topology analysis; a structure nesting module 103b, used to perform Boolean subtraction and Boolean intersection operations with the solid regions and the Neovius structure and the Gyroid structure respectively, to construct a Neovius support skeleton structure with a continuous curved surface and to form a cavity within the Neovius support skeleton structure, and to simultaneously generate a Gyroid infill body with a consistent shape; composite construction Module 103c is used to perform a Boolean union operation on the Neovius load-bearing skeleton structure and the Gyroid filler to generate a Neovius-Gyroid multi-level composite thermal insulation structure with interconnected pores; and the forming and construction module 103d is used to slice the Neovius-Gyroid multi-level composite thermal insulation structure, generate layer-by-layer scanning path data, and use a preset additive manufacturing process to simultaneously complete the layer-by-layer melting and metallurgical bonding of the Neovius load-bearing skeleton structure and the Gyroid filler in the same forming cycle according to the layer-by-layer scanning path data, thereby completing the construction of the Neovius-Gyroid multi-level composite thermal insulation component.

[0135] It should be understood that the apparatus embodiments and method embodiments can correspond to each other, and similar descriptions can be referred to the method embodiments. To avoid repetition, they will not be repeated here. Specifically, the additive manufacturing apparatus 100 can correspond to the corresponding subject in the additive manufacturing method 200 of the present application embodiments, and each unit in the additive manufacturing apparatus 100 is for implementing the corresponding process in the additive manufacturing method 200. For the sake of brevity, they will not be repeated here.

[0136] It should also be understood that the various units in the additive manufacturing apparatus 100 involved in the embodiments of this application are based on logical functional division. In practical applications, the function of one unit can also be implemented by multiple units, or the function of multiple units can be implemented by one unit. Furthermore, these functions can also be implemented with the assistance of one or more other units. For example, some or all of the additive manufacturing apparatus 100 may be merged into one or more additional units. As another example, some units(s) in the additive manufacturing apparatus 100 can be further divided into multiple functionally smaller units, which can achieve the same operation without affecting the technical effects of the embodiments of this application. Furthermore, the additive manufacturing apparatus 100 may also include other units. In practical applications, these functions can also be implemented with the assistance of other units, and can be implemented collaboratively by multiple units.

[0137] It should also be understood that the terms "module" or "unit" used in the embodiments of this application refer to a computer program or part of a computer program that has a predetermined function and works with other related parts to achieve a predetermined goal, and can be implemented wholly or partially using software, hardware (such as processing circuitry or memory), or a combination thereof. Similarly, a processor (or multiple processors or memory) can be used to implement one or more modules or units. Furthermore, each module or unit can be part of an overall module or unit that includes the functionality of that module or unit.

[0138] For example, the additive manufacturing apparatus 100 according to the embodiments of this application, and the method of the embodiments of this application, can be constructed and implemented by running a computer program (including program code) capable of executing the steps involved in the corresponding method on a general-purpose computing device including processing elements and storage elements such as a central processing unit (CPU), random access memory (RAM), and read-only memory (ROM). The computer program can be recorded on, for example, a computer-readable storage medium and loaded into an electronic device through the computer-readable storage medium, and the computer program is used to implement the corresponding method of the embodiments of this application. In other words, the units mentioned above can be implemented in hardware, in software instructions, or in a combination of hardware and software. Specifically, the steps of the method embodiments in the embodiments of this application can be completed by the integrated logic circuits of the hardware in the processor and / or in software instructions. The steps of the method disclosed in the embodiments of this application can be directly embodied as being executed by a hardware decoding processor, or by a combination of hardware and software in the decoding processor. Optionally, the software can be located in a mature storage medium in the art, such as random access memory, flash memory, read-only memory, programmable read-only memory, electrically erasable programmable memory, registers, etc. The software in the memory can be run by a processor to perform the steps described in the method embodiments above.

[0139] Figure 13 A schematic diagram of the structure of an exemplary electronic device according to some embodiments of this application is shown.

[0140] refer to Figure 13 As shown. The electronic device 300 includes at least a processor 310 and a computer-readable storage medium 320. The processor 310 and the computer-readable storage medium 320 can be connected via a bus or other means. The computer-readable storage medium 320 stores a computer program 321, which includes computer instructions. The processor 310 executes the computer instructions stored in the computer-readable storage medium 320. The processor 310 is the computing and control core of the electronic device 300, and is adapted to implement one or more computer instructions, specifically to load and execute one or more computer instructions to achieve a corresponding method flow or function.

[0141] As an example, processor 310 may also be referred to as a central processing unit (CPU). Processor 310 may include, but is not limited to: general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete component gate or transistor logic devices, discrete hardware components, etc.

[0142] As an example, the computer-readable storage medium 320 may be a high-speed RAM memory or a non-volatile memory, such as at least one disk storage device; optionally, it may also be at least one computer-readable storage medium located remotely from the aforementioned processor 310. Specifically, the computer-readable storage medium 320 includes, but is not limited to, volatile memory and / or non-volatile memory. The non-volatile memory may be read-only memory (ROM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), or flash memory. The volatile memory may be random access memory (RAM), which serves as an external cache. By way of example, but not limitation, many forms of RAM are available, such as Static RAM (SRAM), Dynamic RAM (DRAM), Synchronous DRAM (SDRAM), Double Data Rate SDRAM (DDR SDRAM), Enhanced SDRAM (ESDRAM), Synchronous Link DRAM (SLDRAM), and Direct Rambus RAM (DR RAM).

[0143] refer to Figure 13 As shown, the electronic device 300 may also include a transceiver 330.

[0144] The processor 310 can control the transceiver 330 to communicate with other devices; specifically, it can send information or data to other devices or receive information or data sent by other devices. The transceiver 330 may include a transmitter and a receiver. The transceiver 330 may further include antennas, and the number of antennas may be one or more.

[0145] It should be understood that the various components in the electronic device 300 are connected through a bus system, which includes a data bus, a power bus, a control bus, and a status signal bus. It is worth noting that the electronic device 300 can be any type of electronic device with data processing capabilities; the computer-readable storage medium 320 stores first computer instructions; the processor 310 loads and executes the first computer instructions stored in the computer-readable storage medium 320 to implement the corresponding steps in the method embodiments of this application; in specific implementations, the first computer instructions in the computer-readable storage medium 320 are loaded and executed by the processor 310, and to avoid repetition, this will not be described further here.

[0146] According to another aspect of this application, embodiments of this application provide a chip. This chip can be an integrated circuit chip with signal processing capabilities, capable of implementing or executing the methods, steps, and logic block diagrams disclosed in the embodiments of this application. The chip can also be referred to as a system-on-a-chip (SoC), system-on-a-chip (SoC), chip system, or system-on-chip, etc. This chip can be applied to various electronic devices capable of mounting chips, enabling the device with the chip mounted to execute the corresponding steps in the methods or logic block diagrams disclosed in the embodiments of this application. For example, the chip may be suitable for implementing one or more computer instructions, specifically suitable for loading and executing one or more computer instructions to achieve a corresponding method flow or corresponding function.

[0147] According to another aspect of this application, embodiments of this application provide a computer-readable storage medium (Memory). This computer-readable storage medium is a computer's memory device used to store programs and data. It is understood that the computer-readable storage medium here may include both built-in storage media within the computer and, of course, extended storage media supported by the computer. The computer-readable storage medium provides storage space that stores the operating system of an electronic device. This storage space contains computer instructions suitable for loading and execution by a processor. When these computer instructions are read and executed by the processor of the computer device, they cause the computer device to perform the corresponding steps in the methods or logic diagrams disclosed in the embodiments of this application.

[0148] According to another aspect of this application, embodiments of this application provide a computer program product or computer program. The computer program product or computer program includes computer instructions stored in a computer-readable storage medium. A processor of a computer device reads the computer instructions from the computer-readable storage medium and executes the computer instructions, causing the computer device to perform corresponding steps in the methods or logic block diagrams disclosed in the embodiments of this application. In other words, when the solutions provided in this application are implemented using software, they can be implemented in whole or in part as a computer program product or computer program. The computer program product or computer program includes one or more computer instructions. When these computer program instructions are loaded and executed on a computer, all or part of the processes of the embodiments of this application are run or the functions of the embodiments of this application are implemented.

[0149] It is worth noting that the computer involved in this application can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions involved in this application can be stored in a computer-readable storage medium, or can be transmitted from one computer-readable storage medium to another. For example, the computer instructions can be transmitted from one website, computer, server, or data center to another website, computer, server, or data center via wired (e.g., coaxial cable, fiber optic, digital subscriber line (DSL)) or wireless (e.g., infrared, wireless, microwave, etc.) means.

[0150] Those skilled in the art will recognize that the units and process steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. In other words, those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of protection of this application.

[0151] Finally, it should be noted that the above content is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims. For example, the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. Furthermore, various different embodiments of this application can also be arbitrarily combined, as long as they do not violate the basic idea of ​​this application, and they should also be considered as the content disclosed in this application.

[0152] List of reference numerals in the attached diagram:

[0153] 10. Neovius-Gyroid multi-level composite thermal insulation components

[0154] 11. Neovius structure

[0155] 12. Gyroid structure

[0156] 100. Additive Manufacturing Equipment

[0157] 101. Additive Manufacturing Equipment

[0158] 102. Terminal equipment

[0159] 103. Control Unit

[0160] 103a. Structural Construction Module

[0161] 103b. Calculation and processing module

[0162] 103c, Composite Building Blocks

[0163] 103d, Forming Control Module

[0164] 104. Vacuum drying equipment

[0165] 105. Post-processing equipment

[0166] 106. Cleaning equipment

[0167] 300. Electronic equipment

[0168] 310. Processor

[0169] 320. Computer-readable storage media

[0170] 321. Computer Programs

[0171] 330. Transceiver

Claims

1. An additive manufacturing method for a Neovius-Gyroid multi-level composite thermal insulation component, characterized in that, The method includes: Neovius and Gyroid structures are constructed separately, and based on the geometric features of the Neovius structure, geometric topology analysis is used to separate the solid regions of the Neovius structure, including the body center, face center, edges, and vertices. The solid region is subjected to Boolean subtraction and Boolean intersection operations with the Neovius structure and the Gyroid structure respectively to construct a Neovius support skeleton structure with a continuous curved surface and form a cavity within the Neovius support skeleton structure, and simultaneously generate a Gyroid infill body with a consistent shape. Performing a Boolean union operation on the Neovius support frame structure and the Gyroid filler generates a Neovius-Gyroid multi-level composite thermal insulation structure with interconnected pores; and, The Neovius-Gyroid multi-level composite thermal insulation structure is sliced ​​to generate layer-by-layer scanning path data. Using a preset additive manufacturing process, the Neovius load-bearing skeleton structure and Gyroid filler are melted and metallurgically bonded layer by layer in the same forming cycle according to the layer-by-layer scanning path data, thereby completing the construction of the Neovius-Gyroid multi-level composite thermal insulation component.

2. The method according to claim 1, characterized in that, The construction of the Neovius and Gyroid structures respectively includes: A Neovius structure is constructed using implicit functions on a three-period minimal surface: The implicit function's left-hand side is the governing equation of the Neovius structure. The value of affects the relative density of the Neoviius structure; and, Constructing the Gyroid structure for internal padding: The implicit function on the left side of the equation is the governing equation of the Gyroid structure, and L is the size of the lattice unit to ensure that the unit cell has the same period in the x, y, and z directions. The value of affects the relative density of the Gyroid structure.

3. The method according to claim 2, characterized in that, Based on the geometric characteristics of the Neovius structure, geometric topology analysis is used to separate the solid regions of the Neovius structure, including one or more of the following: body center, face center, edges, and vertices. Based on the geometric topology of the Neovius unit cell, the solid region of the Neovius structure is deconstructed into geometric features including body center, face center, edges and vertices, and different geometric tool size parameters are set according to the spatial size of different geometric features, wherein the geometric features are presented in an approximately spherical or hemispherical shape. Using a sphere with a first preset radius as the Boolean operation tool, perform Boolean intersection operations with the Neovius structure: ,in For the separated body-centered solid block, The Neovius support framework is a sphere with a first predetermined radius; and, Using a sphere with a second preset radius as the Boolean operation tool, the same Boolean intersection operation is performed on the edge and vertex features respectively: ,in The separated edge solid blocks and corner solid blocks, The Neovius support skeleton structure, A sphere with a second preset radius.

4. The method according to claim 3, characterized in that, Performing a Boolean union operation on the Neovius support frame structure and the Gyroid filler generates a Neovius-Gyroid multi-layer composite thermal insulation structure with interconnected pores, including: Perform Boolean subtraction operations between the Neovius structure and the body center, edge, and corner solid blocks respectively: ,in The Neovius support skeleton structure, For the separated body-centered solid block, For the separated edge and corner solid blocks, a Neovius load-bearing skeleton structure is formed, and a cavity structure with the same shape as the target solid region is formed within it. Perform Boolean intersection operations between the Gyroid structure and the solid blocks at the body center, edges, and vertices, respectively: ,in It is a Gyroid structure. For the separated body-centered solid block, For the separated edge and corner solid blocks, generate Gyroid fillers that match the spatial morphology of the cavity structure; and, Performing a Boolean union operation on the Neovius support frame and the Gyroid filler generates a Neovius-Gyroid multi-level composite thermal insulation structure. The exterior is rigidly supported by the Neovius support frame, while the interior is filled with the Gyroid filler within a cavity, creating interconnected pores. The Gyroid filler is located at least partially within the body center, edge, or apex region of the Neovius support structure, and a continuous connection boundary is formed between the Gyroid filler and the Neovius support skeleton.

5. The method according to claim 1 or 4, characterized in that, The Neovius-Gyroid multi-layer composite thermal insulation structure is sliced ​​to generate layer-by-layer scanning path data, including: The Neovius-Gyroid multi-level composite thermal insulation structure is imported into a preset additive processing software; The Neovius-Gyroid multi-level composite thermal insulation structure was optimized in terms of placement and supported. The Neovius-Gyroid multi-level composite thermal insulation structure is sliced ​​along its height direction; and... Based on the sliced ​​Neovius-Gyroid multi-layer composite thermal insulation structure, two-dimensional scanning path data is generated layer by layer.

6. The method according to claim 5, characterized in that, When slicing the Neovius-Gyroid multi-layer composite thermal insulation structure along its height direction, the method includes: Configure one or more scanning strategies among partitioned scanning, interlaced scanning, or rotational scanning; and... The scanning energy density is preset and adjusted according to the local feature size of the structure, wherein the preset adjustment includes at least using a first energy density in the Neovius support skeleton structure region and a second energy density in the Gyroid filler and / or porous region.

7. The method according to claim 1 or 6, characterized in that, When slicing the Neovius-Gyroid multi-level composite thermal insulation structure, the method further includes: Select a preset powder material, wherein the preset powder material is one or more of titanium alloy, high-temperature alloy, stainless steel, or aluminum alloy powder; and, The vacuum drying equipment is controlled to dry the preset powder material at a first preset temperature for a preset time, thereby removing the moisture adsorbed by the preset powder material, and after drying, the preset powder material is cooled to a second preset temperature for later use.

8. The method according to claim 1 or 6, characterized in that, The process employs a pre-defined additive manufacturing process, which, based on the layer-by-layer scanning path data, enables the simultaneous forming of the Neovius load-bearing skeleton structure and the Gyroid filler within the same forming cycle, including: The preset powder material is laid onto the forming area in a layer-by-layer stacking manner; Based on the layer-by-layer scanning path data, energy beam scanning is performed on the pre-set powder materials stacked layer by layer within the same forming cycle to achieve synchronous forming of the Neovius support framework structure and the Gyroid filler; and, The process involves cyclically laying and shaping the pre-set powder materials until the construction of the Neovius-Gyroid multi-level composite thermal insulation component is completed.

9. The method according to claim 1, characterized in that, After completing the construction of the Neovius-Gyroid multi-level composite insulation component, the method includes: The system controls a pre-defined post-processing device to separate the Neovius-Gyroid multi-layer composite thermal insulation component from the substrate, wherein the pre-defined post-processing process includes one or more of wire cutting or machining post-processing devices; and... The preset cleaning equipment is controlled to remove residual powder material in the Neovius-Gyroid multi-level composite thermal insulation component, wherein the preset cleaning equipment includes one or more of high-pressure airflow, sandblasting or ultrasonic vibration cleaning equipment.

10. A Neovius-Gyroid multi-level composite thermal insulation component prepared by the method according to any one of claims 1-9.

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