A high-performance 3D printer and a printing method thereof

Abstract

The application relates to a high-performance 3D printer and a printing method thereof, the printer comprising a base, the top of the base being provided with a protective bin, the inside of the protective bin being provided with a framework, the top of the framework being provided with a forming platform, the framework being connected with the forming platform through a displacement mechanism one, the top of the framework being further provided with a support frame, the support frame being connected with a movable frame through a displacement mechanism two, the movable frame being connected with a printing head through a displacement mechanism three, the front end of the protective bin being provided with a controller, a laser interferometer being further arranged on the framework, and an optical grating ruler being further arranged on the printing head. The application greatly improves the forming size precision of a complex structural part, effectively suppresses the inertial vibration of the printing head during high-speed turning, significantly improves the surface finish, shortens the preheating waiting time, improves the printing efficiency and operation safety, realizes remote task issuing and printing state monitoring, and meets the demand of digital management of equipment of an intelligent manufacturing production line.

Description

Technical Field

[0001] This invention relates to the field of 3D printer technology, specifically to a high-performance 3D printer and its printing method. Background Technology

[0002] With the rapid development of additive manufacturing technology, 3D printers have been widely used in prototyping, mold development, and even direct parts production. Among them, fused deposition modeling (FDM) equipment occupies an important market share due to its relatively controllable cost and wide material adaptability. However, existing FDM 3D printers still face several technical bottlenecks in high-speed, high-precision, and high-reliability manufacturing, which restricts their further expansion into industrial applications.

[0003] In terms of motion control and positioning accuracy, traditional 3D printers often use stepper motors in conjunction with lead screws or open-loop belt drives for their displacement mechanisms, with the movement of the print head and forming platform relying on open-loop control. Due to issues such as elastic deformation and backlash in belt drives, coupled with the cumulative positioning errors that accumulate over long periods of operation, the dimensional accuracy and surface quality of the printed parts are directly affected. Although some high-end equipment attempts to introduce feedback elements such as linear scales, these typically only measure a single motion axis, lacking comprehensive closed-loop correction capabilities for the spatial position of the forming platform and the linear displacement of the print head, making it difficult to meet the high repeatability positioning accuracy requirements of complex components.

[0004] Regarding vibration suppression during high-speed printing, as printing speed increases, the inertial impact of the print head at path inflection points intensifies, easily causing frame resonance and vibration of moving parts, resulting in vibration marks or even interlayer misalignment on the printed surface. Existing methods mostly employ simple acceleration and deceleration handling, lacking forward-looking planning and optimization of the speed curve throughout the entire path, making it difficult to balance high-speed printing with stable operation.

[0005] Regarding heating and preheating mechanisms, FDM processes primarily rely on resistance heating blocks for printhead heating, transferring heat to the molten material via thermal conduction. This approach suffers from high thermal inertia and lag in temperature control response. Simultaneously, the forming platform typically employs only a heated bed for overall heating, resulting in long preheating times, high energy consumption, and limited improvement in adhesion to the bottom of the printed part. While there have been recent explorations of applying induction heating technology to 3D printing, these have mostly focused on post-printing heat treatment or the curing of specific materials. Solutions integrating high-frequency induction heating simultaneously into the printhead and forming platform, and coordinating induction preheating of the moving permanent magnet, are still lacking.

[0006] In terms of intelligent control and anomaly handling, the control systems of existing 3D printers are mostly limited to basic motion command parsing and temperature maintenance, and lack the capability for real-time monitoring and coordinated response to abnormal working conditions such as material depletion and overheating during the printing process. Once a consumable filament break or heating runaway occurs, manual intervention is often required to stop the machine, which leads to print failures and even safety hazards. In addition, the operation data of existing equipment lacks a systematic recording and transmission mechanism, which is not conducive to the traceability of print quality and the remote management of the production process. No solution has been proposed for the related technical problems yet. Summary of the Invention

[0007] Aiming at the problems in the related art, the present invention proposes a high-performance 3D printer and a printing method thereof to overcome the above technical problems existing in the related prior art. The purpose of the present invention is to greatly improve the forming dimensional accuracy of complex structural parts, effectively suppress the inertial vibration of the print head during high-speed steering, solve the problem that traditional 3D printers are prone to layer lines and vibration lines when printing complex contours, significantly improve surface finish, shorten preheating waiting time, improve printing efficiency and operation safety, realize remote task issuance and printing status monitoring, facilitate access to the industrial Internet of Things environment, and meet the demand of intelligent manufacturing production lines for digital equipment management.

[0008] To achieve the above purpose, the present invention provides the following technical solution: a high-performance 3D printer, comprising a base, a protective cabin is arranged on the top of the base, a frame is arranged inside the protective cabin, a forming platform is arranged on the top of the frame, the frame is connected with the forming platform through a first displacement mechanism, a support frame is further arranged on the top of the frame, the support frame is connected with a movable frame through a second displacement mechanism, the movable frame is connected with a print head through a third displacement mechanism, mover permanent magnets are arranged on both the print head and the forming platform, a controller is mounted at the front end of the protective cabin, and a high-frequency induction coil is further arranged on the print head; Each of the first displacement mechanism, the second displacement mechanism and the third displacement mechanism comprises a servo motor, a first pulley, a second pulley, a belt and a connecting block. The servo motors are respectively mounted on the frame, the support frame and the movable frame, the first pulleys are respectively mounted at the output ends of the servo motors, the second pulleys are respectively arranged on the frame, the support frame and the movable frame, the first pulley and the second pulley are connected by the belt, the connecting blocks are respectively fixedly mounted on the forming platform, the movable frame and the print head, and one end of each connecting block is fixedly connected to one side of the belt.

[0009] Preferably, a laser interferometer is further arranged on the frame, a grating ruler is further arranged on the print head, and the laser interferometer and the grating ruler are respectively electrically connected with the controller.

[0010] Preferably, a material breakage sensor is further arranged on the print head, and an audible and visual alarm is arranged on the outer wall of the protective cabin.

[0011] Preferably, the controller includes a main control module, a motion control module, a temperature control module, a position closed-loop adjustment module, and an induction heating drive module, wherein the main control module is electrically connected to the motion control module, the temperature control module, the position closed-loop adjustment module, and the induction heating drive module, respectively. The main control module is used to parse externally input files and generate motion commands, temperature commands, and heating commands. The temperature control module is electrically connected to the printhead and is used to adjust the heating temperature of the printhead according to the temperature command. The position closed-loop adjustment module is electrically connected to the laser interferometer and the grating ruler respectively. It is used to receive the spatial position signal of the forming platform detected by the laser interferometer and the linear displacement signal of the print head detected by the grating ruler, and to perform real-time correction on the pulse signal output by the motion control module based on the spatial position signal and the linear displacement signal. The induction heating drive module is electrically connected to the high-frequency induction coil and is used to output a high-frequency alternating current to the high-frequency induction coil according to the heating command to induction preheat the moving permanent magnet.

[0012] Preferably, the controller further includes a speed look-ahead planning module, which is electrically connected to the main control module and the motion control module respectively. The speed look-ahead planning module is used to pre-calculate the speed change curves of displacement mechanism one, displacement mechanism two and displacement mechanism three at the inflection point based on the path point coordinates in the code file and the preset acceleration / deceleration parameters, and output the speed optimization value to the motion control module to suppress the vibration of the print head when turning.

[0013] Preferably, the controller further includes a material shortage detection module and an alarm module; The material shortage detection module and the material shortage sensor are electrically connected and are used to send a material shortage signal to the main control module when a material shortage is detected. The alarm module and the audible and visual alarm are electrically connected. When the material breakage signal or the over-temperature signal fed back by the temperature control module is received, the audible and visual alarm is driven to issue an audible and visual alarm. At the same time, the main control module suspends the output of the motion control module and the induction heating drive module.

[0014] Preferably, the controller further includes a data storage module and a wireless communication module; The data storage module and the main control module are electrically connected and are used to cache the file and record log data during the printing process; The wireless communication module and the main control module are electrically connected and are used to wirelessly interact with an external host computer or cloud platform to receive remote printing tasks or upload the log data.

[0015] To achieve the above objectives, the present invention also provides the following technical solution: A printing method for a high-performance 3D printer, applied to a high-performance 3D printer as described above, includes the following steps: Step S1: Start the controller. The main control module parses the externally input file and generates motion commands, temperature commands, and heating commands. Step S2: The temperature control module controls the print head to heat to a preset temperature according to the temperature command. At the same time, the induction heating drive module outputs a high-frequency alternating current to the high-frequency induction coil according to the heating command to induction preheat the forming platform and the moving permanent magnet on the print head. Step S3: The motion control module drives the servo motor to rotate according to the motion command, and drives the molding platform, movable frame and print head to move in their respective directions through the pulley one, pulley two, belt and connecting block respectively; Step S4: During the movement, the laser interferometer detects the spatial position signal of the forming platform in real time, and the grating ruler detects the linear displacement signal of the print head in real time, and sends them to the position closed-loop adjustment module respectively. Step S5: The position closed-loop adjustment module corrects the pulse signal output by the motion control module in real time based on the received spatial position signal and the linear displacement signal to compensate for motion errors; Step S6: The print head prints layer by layer on the forming platform until the three-dimensional object is formed.

[0016] Preferably, in step S3, the speed look-ahead planning module pre-calculates the speed change curves of displacement mechanism one, displacement mechanism two, and displacement mechanism three at the inflection point based on the path point coordinates in the file and the preset acceleration / deceleration parameters, and outputs the speed optimization value to the motion control module to suppress the vibration of the print head when turning.

[0017] Preferably, in any of steps S1 to S6, when the material shortage detection module detects a material shortage, it sends a material shortage signal to the main control module; or when the temperature control module detects an over-temperature, it sends an over-temperature signal to the main control module; upon receiving the material shortage signal or the over-temperature signal, the main control module immediately suspends the output of the motion control module and the induction heating drive module, and simultaneously the alarm module drives the audible and visual alarm to issue an audible and visual alarm.

[0018] Compared with the prior art, the beneficial effects of the present invention are: This invention relates to a high-performance 3D printer and its printing method. By setting up a laser interferometer and a grating ruler, and combining them with a position closed-loop adjustment module, the spatial position of the forming platform and the linear displacement of the print head can be detected in real time. The main control module corrects the pulse signal output by the motion control module in real time, effectively eliminating the cumulative error caused by elastic deformation, backlash, or long-term wear in belt drive, ensuring that the positioning accuracy of the print head can reach the micron level, and significantly improving the forming dimensional accuracy of complex structural parts. This invention relates to a high-performance 3D printer and its printing method. By setting a speed look-ahead planning module to pre-calculate the speed change curves of displacement mechanism one, displacement mechanism two, and displacement mechanism three at the inflection point of the path, and outputting the speed optimization value, the motion control module can smoothly decelerate before the inflection point and smoothly accelerate after exiting the curve. This effectively suppresses the inertial vibration of the print head when turning at high speed, solves the problem of layer texture and vibration texture that traditional 3D printers are prone to when printing complex contours, and significantly improves the surface finish. This invention relates to a high-performance 3D printer and its printing method. By setting a moving permanent magnet in both the print head and the forming platform, and cooperating with a high-frequency induction coil and an induction heating drive module, the moving permanent magnet is preheated non-contactly while the print head is heated to a preset temperature. This allows the forming platform and the print head to reach thermal equilibrium before the actual printing, avoiding the waiting time caused by the long heat conduction required by traditional heated beds. It is especially suitable for multi-batch, rapid switching printing scenarios, and the overall printing preparation time can be shortened by more than 30%. This invention relates to a high-performance 3D printer and its printing method. By setting up a material breakage detection module and a temperature control module to monitor the material status and heating temperature respectively, once the material breakage or overheating is detected, the main control module immediately suspends motion control and induction heating drive output. At the same time, the alarm module drives the audible and visual alarm to sound an alarm. This can prevent the print head from burning the nozzle when there is no material and avoid the risk of fire caused by overheating, thus greatly improving the safety of equipment operation. This invention relates to a high-performance 3D printer and its printing method. By setting up a main control module, motion control module, temperature control module, position closed-loop adjustment module, and induction heating drive module that are independently divided yet work collaboratively, the coupling between functions is reduced, which is beneficial for later firmware upgrades or adjustments to heating and motion parameters for different materials. A data storage module can cache print files and record logs, and a wireless communication module supports interaction with a host computer or cloud platform, enabling remote task distribution and printing status monitoring. This facilitates integration with the Industrial Internet of Things (IIoT) environment and meets the digital management needs of intelligent manufacturing production lines. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of the 3D printer of the present invention; Figure 2This is a frontal structural diagram of the skeleton of the 3D printer of the present invention; Figure 3 This is a rear view structural schematic diagram of the skeleton of the 3D printer of the present invention; Figure 4 This is a schematic diagram of the controller of the 3D printer of the present invention.

[0020] 1. Base; 2. Protective chamber; 3. Frame; 4. Molding platform; 5. Support frame; 6. Movable frame; 7. Print head; 8. Moving permanent magnet; 9. Controller; 901. Main control module; 902. Motion control module; 903. Temperature control module; 904. Position closed-loop adjustment module; 905. Induction heating drive module; 906. Speed ​​look-ahead planning module; 907. Material breakage detection module; 908. Alarm module; 909. Data storage module; 910. Wireless communication module; 10. High-frequency induction coil; 11. Servo motor; 12. Belt pulley one; 13. Belt pulley two; 14. Belt; 15. Connecting block; 16. Laser interferometer; 17. Grating ruler. Detailed Implementation

[0021] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Example

[0022] Please see Figure 1-4As shown, this invention proposes a technical solution for a high-performance 3D printer and its printing method: A high-performance 3D printer includes a base 1, a protective chamber 2 on the top of the base 1, a frame 3 inside the protective chamber 2, a forming platform 4 on the top of the frame 3, the frame 3 being connected to the forming platform 4 via a displacement mechanism, a support frame 5 on the top of the frame 3, a movable frame 6 connected to the support frame 5 via a displacement mechanism, a print head 7 connected to the movable frame 6 via a displacement mechanism, a moving permanent magnet 8 on both the print head 7 and the forming platform 4, a controller 9 installed at the front end of the protective chamber 2, and a high-frequency induction coil 10 on the print head 7; specifically, the base 1 adopts an integrated cast iron or marble / granite structure, and the base 1's bottom... The machine is equipped with adjustable shock-absorbing feet to absorb mechanical vibrations generated by the high-speed movement of displacement mechanism 1, displacement mechanism 2, or displacement mechanism 3 during printing, ensuring the rigidity of the entire machine and printing stability. The protective chamber 2 is a transparent sealed chamber made of double-layer tempered glass or polycarbonate transparent panel. Its inner wall is covered with a heat insulation layer to maintain a constant temperature environment inside the chamber and reduce the impact of temperature fluctuations on the forming accuracy. The protective chamber 2 also has an operation window and is equipped with sealed gloves to facilitate manual intervention in a closed state. Displacement mechanism 1 can adjust the front and rear position of the forming platform 4, displacement mechanism 2 can adjust the height of the movable frame 6 to adjust the height of the print head 7, and displacement mechanism 3 can adjust the lateral position of the print head 7. The frame 3 is a gantry-type or cantilever-type high-rigidity metal frame, with triangular support ribs reinforcing the beams and columns to resist the reaction force generated when the print head 7 moves; the forming platform 4 is a heatable aluminum substrate or microcrystalline glass platform, with a thermistor and heating film embedded inside to heat the bottom of the printed parts and prevent them from warping; the support frame 5 spans the frame 3 to ensure the parallelism between the installation reference surface of the displacement mechanism 2 and the working surface of the forming platform 4. Displacement mechanisms one, two, and three each include a servo motor 11, pulley one 12, pulley two 13, belt 14, and connecting block 15. Servo motors 11 are mounted on the frame 3, support frame 5, and movable frame 6. Pulley one 12 is mounted on the output end of each servo motor 11. Pulley two 13 is mounted on each of the frame 3, support frame 5, and movable frame 6. Pulley one 12 and pulley two 13 are connected by belt 14. Connecting blocks 15 are fixedly mounted on the forming platform 4, movable frame 6, and print head 7. One end of the connecting block 15 is fixedly connected to one side of belt 14. Specifically, starting the servo motor 11 drives pulley one 12, which is fixedly connected to it, to rotate clockwise or counterclockwise. When wheel 12 rotates, it drives pulley 13, which is connected to belt 14, to rotate. When belt 14 is in operation, it drives connecting block 15, which is fixedly connected to it, to move. Both pulley 12 and pulley 13 are high-precision synchronous pulleys with circular arc teeth or trapezoidal teeth. Belt 14 is a reinforced polyurethane synchronous belt with steel wire or aramid fiber embedded inside. A tensioning pulley is provided on its back to automatically adjust the belt tension and eliminate the loosening phenomenon caused by long-term operation of belt 14. Connecting block 15 is fixedly connected to one side of belt 14 by pressure plate and screws. The other side of connecting block 15 is slidably engaged with the corresponding linear guide rail through linear bearing, thereby converting the rotational motion of belt 14 into linear motion and ensuring backlash-free transmission.

[0023] Please see Figure 2-3 As shown, a laser interferometer 16 is further provided on the skeleton 3, and a grating ruler 17 is provided on the print head 7. The laser interferometer 16 and the grating ruler 17 are electrically connected to the controller 9 respectively.

[0024] In this embodiment, the laser beam emitted by the laser interferometer 16 is projected onto the reflective mirror surface on the forming platform 4 to measure the actual spatial coordinates of the forming platform 4 in the X, Y, and Z axes in real time, with a measurement resolution of up to the nanometer level. The grating ruler 17 is a closed glass grating or metal grating, and its reading head is fixed on the print head 7. The scale grating is used to directly measure the linear displacement of the print head 7 relative to the movable frame 6. The laser interferometer 16 and the grating ruler 17 form a dual closed-loop feedback system, in which the laser interferometer 16 serves as an absolute position reference and the grating ruler 17 serves as a relative position increment reference. The two work together to compensate for errors in the mechanical transmission chain.

[0025] Furthermore, a material breakage sensor is installed on the print head 7, and an audible and visual alarm is installed on the outer wall of the protective chamber 2.

[0026] In this embodiment, the filament breakage sensor is a photoelectric through-beam sensor or a mechanical micro-switch sensor, which is installed at the feed channel inlet of the printhead 7. When the filament passes through, the filament breakage sensor outputs a low-level signal, and when the filament breaks or runs out, the filament breakage sensor outputs a high-level interrupt signal. The audible and visual alarm includes an LED red warning light and a piezoelectric buzzer, which are used to provide dual visual and audible warnings in abnormal conditions, so that operators can remotely and promptly detect faults.

[0027] Please see Figure 4 As shown, the controller 9 further includes a main control module 901, a motion control module 902, a temperature control module 903, a position closed-loop adjustment module 904, and an induction heating drive module 905. The main control module 901 is electrically connected to the motion control module 902, the temperature control module 903, the position closed-loop adjustment module 904, and the induction heating drive module 905, respectively. The main control module 901 is used to parse externally input files and generate motion commands, temperature commands, and heating commands; The temperature control module 903 is electrically connected to the printhead 7 and is used to adjust the heating temperature of the printhead 7 according to the temperature command. The position closed-loop adjustment module 904 is electrically connected to the laser interferometer 16 and the grating ruler 17 respectively. It is used to receive the spatial position signal of the forming platform 4 detected by the laser interferometer 16 and the linear displacement signal of the print head 7 detected by the grating ruler 17, and to perform real-time correction on the pulse signal output by the motion control module 902 based on the spatial position signal and the linear displacement signal. The induction heating drive module 905 is electrically connected to the high-frequency induction coil 10 and is used to output a high-frequency alternating current to the high-frequency induction coil 10 according to the heating command to induction preheat the moving permanent magnet 8.

[0028] In this embodiment, the main control module 901 uses an ARM Cortex-M7 or a higher-performance MCU or FPGA as the core processor. It integrates a file parsing engine, which supports reading slice files in standard G code or CLI format. It can parse the coordinate axis movement instructions (G0 / G1), temperature setting instructions (M104 / M109), and M code auxiliary instructions in the file line by line, convert them into a timestamped instruction queue, and distribute them to the corresponding execution modules according to priority. The temperature control module 903 adopts a PID (proportional-integral-derivative) plus feedforward control algorithm. It collects real-time temperature values ​​through thermocouples or thermistors integrated on the printhead 7, uses the temperature command as the target value, and controls the duty cycle of the heating rod of the printhead 7 through pulse width modulation (PWM) signal to achieve precise adjustment of the heating temperature. Its temperature control accuracy can reach ±0.5℃. At the same time, the temperature control module 903 has an over-temperature hardware protection circuit. When the detected temperature exceeds the safety threshold, the heating power can be directly cut off without the intervention of the main control module. The position closed-loop adjustment module 904 integrates a position comparator and an error compensation algorithm unit. Its workflow is as follows: First, it receives the theoretical pulse signal output by the motion control module 902 as the position command value, and simultaneously acquires the spatial position signal fed back by the laser interferometer 16 and the linear displacement signal fed back by the grating ruler 17 in real time; then, it performs a differential comparison between the feedback signal and the command value to obtain the spatial positioning error and the linear repetition error; finally, the error compensation algorithm generates an additional correction pulse signal based on the error value, which is superimposed on the output of the motion control module 902 to fine-tune the rotation angle of the servo motor 11, thereby eliminating the positioning deviation caused by belt elastic deformation, thermal expansion or mechanical clearance, and ensuring that the relative motion accuracy between the print head 7 and the forming platform 4 reaches the micron level. The induction heating drive module 905 includes a rectifier and filter circuit, a high-frequency inverter circuit (such as a MOSFET or IGBT full-bridge inverter), and a resonant matching network. It outputs a high-frequency alternating current (20kHz~100kHz) to the high-frequency induction coil 10 according to the heating command. The high-frequency induction coil 10 is wound with Litz wire made of multiple strands of enameled wire to reduce skin effect losses. When the high-frequency alternating current passes through the induction coil 10, the generated alternating magnetic field acts on the metal conductive layer or magnetic material inside the moving permanent magnet 8, causing eddy currents and hysteresis losses, thereby achieving non-contact internal preheating. This preheating method can preheat the moving permanent magnet 8 to a set temperature below the Curie temperature before printing begins, effectively reducing the magnetic performance decay of the permanent magnet in low-temperature environments and preventing overheating and demagnetization of the permanent magnet due to heat conduction from the printhead 7.

[0029] Please see Figure 4 As shown, the controller 9 further includes a speed look-ahead planning module 906, which is electrically connected to the main control module 901 and the motion control module 902 respectively. It is used to pre-calculate the speed change curves of displacement mechanism 1, displacement mechanism 2 and displacement mechanism 3 at the inflection point based on the path point coordinates in the code file and the preset acceleration / deceleration parameters, and output the speed optimization value to the motion control module 902 to suppress the vibration of the print head 7 when turning.

[0030] In this embodiment, the speed look-ahead planning module 906 adopts an acceleration (Jerk) control algorithm based on an S-shaped or sinusoidal speed curve. It pre-reads the coordinate data of multiple consecutive path points in the instruction queue of the main control module 901, identifies inflection points and small line segment connections in the path, and then, based on the preset maximum acceleration, maximum deceleration, and acceleration limit values, combined with the inflection point angle and radius of curvature, pre-calculates the deceleration start point required by displacement mechanism one, displacement mechanism two, and displacement mechanism three before reaching the inflection point and the acceleration recovery point after leaving the inflection point, and plans a smooth speed transition curve. The speed optimization value output by the speed look-ahead planning module 906 is directly used as the input of the motion control module 902, enabling the servo motor 11 to achieve smooth speed switching at the inflection point, avoiding mechanical shock and resonance caused by sudden speed changes, significantly suppressing the vibration generated by the print head 7 when turning at high speed, and thus improving the surface finish and dimensional accuracy of the printed parts.

[0031] Please see Figure 4 As shown, the controller 9 further includes a material breakage detection module 907 and an alarm module 908; The material shortage detection module 907 is electrically connected to the material shortage sensor and is used to send a material shortage signal to the main control module 901 when a material shortage is detected. The alarm module 908 is electrically connected to the audible and visual alarm. When it receives a material breakage signal or an over-temperature signal fed back by the temperature control module 903, it drives the audible and visual alarm to issue an audible and visual alarm. At the same time, the main control module 901 suspends the output of the motion control module 902 and the induction heating drive module 905.

[0032] In this embodiment, the material breakage detection module 907 has a built-in debouncing filter circuit, which can perform hardware debouncing processing on the level signal output by the material breakage sensor to prevent false triggering caused by burrs on the surface of the consumable filament. When it is confirmed that the material breakage signal has been valid for more than a set time (e.g., 200ms), the material breakage detection module 907 sends an interrupt priority material breakage signal to the main control module 901. The alarm module 908 has multi-level alarm logic: when a material breakage signal is received, the audible and visual alarm is driven to flash at a frequency of 1Hz and beep intermittently; when an over-temperature signal is received, the audible and visual alarm is driven to flash rapidly at a frequency of 5Hz and beep continuously to distinguish the fault type. At the same time, after triggering the alarm, the main control module 901 will immediately pause the output of the motion control module 902 and the induction heating drive module 905, and save the current printing breakpoint coordinates to the data storage module 909 so as to realize the breakpoint resume printing function after material replacement.

[0033] Please see Figure 4 As shown, the controller 9 further includes a data storage module 909 and a wireless communication module 910; The data storage module 909 and the main control module 901 are electrically connected and are used to cache files and record log data during the printing process; The wireless communication module 910 and the main control module 901 are electrically connected and are used to wirelessly interact with an external host computer or cloud platform to receive remote printing tasks or upload log data.

[0034] In this embodiment, the data storage module 909 uses a high-capacity NAND Flash or SD card as the storage medium. Its internal structure is divided into a code file cache area, a log recording area, and a system parameter area. The log recording area records the real-time temperature curve, motor drive current, position deviation value, and alarm events during the printing process in a cyclic overwrite manner, forming a traceable quality traceability report. The wireless communication module 910 supports Wi-Fi, Bluetooth, or 4G / 5G cellular communication. It has a built-in TCP / IP protocol stack and MQTT IoT protocol, which can realize bidirectional communication with an external host computer or cloud platform: on the one hand, it receives remotely issued print task files or firmware upgrade packages, and on the other hand, it uploads the log data in the data storage module 909 to the cloud platform in real time, allowing users to remotely monitor and analyze the data through a mobile APP or Web terminal. Example

[0035] Please see Figure 1-4 As shown, this invention proposes a printing method for a high-performance 3D printer, applied to the high-performance 3D printer described above, comprising the following steps: Step S1: Start the controller 9. The main control module 901 parses the externally input file and generates motion commands, temperature commands, and heating commands. Step S2: The temperature control module 903 controls the print head 7 to heat to the preset temperature according to the temperature command. At the same time, the induction heating drive module 905 outputs a high-frequency alternating current to the high-frequency induction coil 10 according to the heating command to induction preheat the moving permanent magnet 8 on the forming platform 4 and the print head 7. Step S3: The motion control module 902 drives the servo motor 11 to rotate according to the motion command, and drives the molding platform 4, the movable frame 6 and the print head 7 to move in their respective directions through the pulley 12, pulley 2 13, belt 14 and connecting block 15 respectively. Step S4: During the movement, the laser interferometer 16 detects the spatial position signal of the forming platform 4 in real time, and the grating ruler 17 detects the linear displacement signal of the print head 7 in real time, and sends them to the position closed-loop adjustment module 904 respectively. Step S5: The position closed-loop adjustment module 904 corrects the pulse signal output by the motion control module 902 in real time based on the received spatial position signal and linear displacement signal to compensate for motion errors; Step S6: The print head 7 prints layer by layer on the forming platform 4 until the three-dimensional object is formed.

[0036] In this embodiment, step S1 is the initialization and instruction generation stage. Controller 9 is the control core of the entire device, and the main control module 901, as the central hub of the controller, is responsible for reading externally input G-code or slice files. The core function of the main control module 901 is parsing, that is, extracting parameters such as geometric path, printing temperature, and platform preheating from the file and converting them into three types of low-level execution instructions: motion instructions (for controlling servo motor 11), temperature instructions (for controlling print head 7 heating), and heating instructions (for controlling induction preheating). This step realizes the first conversion from digital model to machine action.

[0037] Step S2 is a parallel preheating and heating step. The temperature control module 903 uses conventional resistance heating or thermocouple closed-loop control to heat the print head 7 (extrusion nozzle) to the preset temperature required for material melting (such as 200℃ for PLA or 240℃ for ABS). The induction heating drive module 905 is a non-contact heating technology. The induction heating drive module 905 passes a high-frequency alternating current to the high-frequency induction coil 10 to generate an alternating magnetic field. This magnetic field will generate eddy currents in the nearby metal conductor (here, the forming platform 4 and the moving permanent magnet 8), thereby achieving rapid and uniform induction preheating. Preheating the forming platform can prevent the printed parts from warping, and preheating the moving permanent magnet can reduce the impact of its thermal expansion on motion accuracy and improve the working efficiency of the servo motor 11 in high-temperature environments.

[0038] Step S3 is the motion execution step. Servo motor 11 refers to a high-precision motor with encoder feedback, which is faster and smoother than stepper motor. The power transmission path is: servo motor 11 → pulley 12 (driving pulley) → belt 14 → pulley 13 (driven pulley) → connecting block 15 (fixed on the belt).

[0039] Step S4 is the high-precision position feedback stage. The laser interferometer 16 is a nanometer-level displacement measurement device based on the principle of optical wave interference. It is used to detect the spatial position of the forming platform 4 (which may include the actual coordinates in the three dimensions of X, Y, and Z), and its accuracy is much higher than that of ordinary encoders. The grating ruler 17 is a common high-precision linear displacement sensor used to detect the linear displacement of the print head 7 (usually the linear movement in a certain axis).

[0040] The laser interferometer 16 and the grating ruler 17 work in parallel, respectively sending the actual position signal to the position closed-loop adjustment module 904 in real time, providing a real data reference for the next step of error compensation.

[0041] Step S5 is the closed-loop error compensation step. The position closed-loop adjustment module 904 compares the actual position fed back in step S4 with the command position issued in step S1 in real time, and calculates the deviation between the two (i.e., motion error, such as error caused by belt elastic deformation, thermal expansion, mechanical clearance, etc.). Then, the position closed-loop adjustment module 904 dynamically adjusts the pulse frequency or number (i.e., the drive command of the servo motor) output by the motion control module 902, so that the actual position infinitely approaches the command position.

[0042] Step S6 is the final stage of the layer-by-layer deposition modeling process. After the coordinated work of all the preceding temperature, motion, feedback, and compensation steps, the print head 7 extrudes molten material onto the forming platform 4 according to the slicing path. After completing one layer, it rises to the next layer thickness and prints the next layer, repeating this cycle until the entire three-dimensional object is completely formed. This is the standard process flow for FDM (Fused Deposition Modeling), but this method significantly improves the quality of the process through the aforementioned high-precision control.

[0043] Furthermore, in step S3, the speed look-ahead planning module 906 pre-calculates the speed change curves of displacement mechanism one, displacement mechanism two and displacement mechanism three at the inflection point based on the path point coordinates in the file and the preset acceleration / deceleration parameters, and outputs the speed optimization value to the motion control module 902 to suppress the vibration of the print head 7 when turning.

[0044] In this embodiment, the speed look-ahead planning module 906 scans multiple subsequent path points in the file in advance. Combining the coordinates of each path point with the preset acceleration / deceleration limit values, it pre-calculates how displacement mechanisms one, two, and three should smoothly decelerate, turn, and then accelerate again at the path inflection points. This generates a smooth speed change curve (such as an S-curve or trapezoidal curve) instead of abrupt speed jumps. The optimized speed command is then output to the motion control module 902, which avoids sudden stops and starts of the motor at corners, thereby effectively suppressing the mechanical vibration of the print head 7, reducing layering, and ensuring high speed without sacrificing surface quality.

[0045] Furthermore, in any of steps S1 to S6, when the material shortage detection module 907 detects a material shortage, it sends a material shortage signal to the main control module 901; or when the temperature control module 903 detects an over-temperature, it sends an over-temperature signal to the main control module 901. After receiving the material shortage signal or the over-temperature signal, the main control module 901 immediately suspends the output of the motion control module 902 and the induction heating drive module 905, and at the same time, the alarm module 908 drives the audible and visual alarm to issue an audible and visual alarm.

[0046] In this embodiment, the monitoring scope covers the status of consumables (the filament breakage detection module 907 typically uses a mechanical switch or optical sensor to detect the presence or absence of filament) and temperature safety (the temperature control module 903 monitors whether the printhead or heated bed exceeds a safety threshold, such as exceeding a set value +10°C). Once any abnormality is triggered, a fault signal is immediately sent to the main control module 901. Upon receiving the signal, the main control module 901 suspends the motion control module 902 (to prevent damage to the forming platform 4) and simultaneously suspends the induction heating drive module 905 (to cut off the high-frequency, high-current flow and prevent further overheating or electromagnetic interference). The alarm module 908 drives the audible and visual alarm to issue a clear audible and visual alert to notify the operator to handle the situation promptly, ensuring the safe operation of the equipment when unattended.

[0047] In the description of this invention, it should be understood that the terms "coaxial," "bottom," "one end," "top," "middle," "other end," "upper," "side," "top," "inner," "front," "center," "both ends," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0048] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "setting," "connection," "fixing," "screw connection," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components or the interaction between two components. Unless otherwise explicitly limited, those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0049] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-performance 3D printer, characterized in that, The system includes a base (1), a protective chamber (2) on the top of the base (1), a frame (3) inside the protective chamber (2), a forming platform (4) on the top of the frame (3), the frame (3) being connected to the forming platform (4) via a displacement mechanism one, a support frame (5) on the top of the frame (3), a movable frame (6) connected to the support frame (5) via a displacement mechanism two, a print head (7) connected to the movable frame (6) via a displacement mechanism three, a moving permanent magnet (8) on both the print head (7) and the forming platform (4), a controller (9) installed at the front end of the protective chamber (2), and a high-frequency induction coil (10) on the print head (7). The displacement mechanism one, displacement mechanism two and displacement mechanism three each include a servo motor (11), a pulley one (12), a pulley two (13), a belt (14) and a connecting block (15). The frame (3), support frame (5) and movable frame (6) are all equipped with servo motors (11). The output end of the servo motor (11) is equipped with a pulley one (12). The frame (3), support frame (5) and movable frame (6) are all equipped with pulley two (13). The pulley one (12) and pulley two (13) are connected by a belt (14). The forming platform (4), movable frame (6) and print head (7) are all fixedly equipped with a connecting block (15). One end of the connecting block (15) is fixedly connected to one side of the belt (14).

2. The high-performance 3D printer according to claim 1, characterized in that: A laser interferometer (16) is also provided on the skeleton (3), and a grating ruler (17) is also provided on the print head (7). The laser interferometer (16) and the grating ruler (17) are electrically connected to the controller (9).

3. A high-performance 3D printer according to claim 2, characterized in that: The print head (7) is also equipped with a material breakage sensor, and the outer wall of the protective chamber (2) is equipped with an audible and visual alarm.

4. A high-performance 3D printer according to claim 3, characterized in that: The controller (9) includes a main control module (901), a motion control module (902), a temperature control module (903), a position closed-loop adjustment module (904), and an induction heating drive module (905). The main control module (901) is electrically connected to the motion control module (902), the temperature control module (903), the position closed-loop adjustment module (904), and the induction heating drive module (905), respectively. The main control module (901) is used to parse externally input files and generate motion commands, temperature commands, and heating commands; The temperature control module (903) is electrically connected to the print head (7) and is used to adjust the heating temperature of the print head (7) according to the temperature command. The position closed-loop adjustment module (904) is electrically connected to the laser interferometer (16) and the grating ruler (17) respectively. It is used to receive the spatial position signal of the molding platform (4) detected by the laser interferometer (16) and the linear displacement signal of the print head (7) detected by the grating ruler (17), and to perform real-time correction on the pulse signal output by the motion control module (902) based on the spatial position signal and the linear displacement signal. The induction heating drive module (905) is electrically connected to the high-frequency induction coil (10) and is used to output a high-frequency alternating current to the high-frequency induction coil (10) according to the heating command to induction preheat the moving permanent magnet (8).

5. A high-performance 3D printer according to claim 4, characterized in that: The controller (9) also includes a speed look-ahead planning module (906), which is electrically connected to the main control module (901) and the motion control module (902) respectively. It is used to pre-calculate the speed change curves of displacement mechanism one, displacement mechanism two and displacement mechanism three at the inflection point according to the path point coordinates in the code file and the preset acceleration / deceleration parameters, and output the speed optimization value to the motion control module (902) to suppress the vibration of the print head (7) when turning.

6. A high-performance 3D printer according to claim 5, characterized in that: The controller (9) also includes a material breakage detection module (907) and an alarm module (908). The material shortage detection module (907) and the material shortage sensor are electrically connected and are used to send a material shortage signal to the main control module (901) when a material shortage is detected. The alarm module (908) is electrically connected to the audible and visual alarm, and is used to drive the audible and visual alarm to issue an audible and visual alarm when the material break signal or the over-temperature signal fed back by the temperature control module (903) is received. At the same time, the main control module (901) suspends the output of the motion control module (902) and the induction heating drive module (905).

7. A high-performance 3D printer according to claim 6, characterized in that: The controller (9) also includes a data storage module (909) and a wireless communication module (910). The data storage module (909) and the main control module (901) are electrically connected and are used to cache the file and record log data during the printing process; The wireless communication module (910) and the main control module (901) are electrically connected and used to wirelessly interact with an external host computer or cloud platform to receive remote printing tasks or upload the log data.

8. A printing method for a high-performance 3D printer, applied to a high-performance 3D printer as described in any one of claims 1 to 7, characterized in that, Includes the following steps: Step S1: Start the controller (9), and the main control module (901) parses the externally input file to generate motion commands, temperature commands and heating commands; Step S2: The temperature control module (903) controls the print head (7) to heat to the preset temperature according to the temperature command. At the same time, the induction heating drive module (905) outputs a high-frequency alternating current to the high-frequency induction coil (10) according to the heating command to induction preheat the moving permanent magnet (8) on the molding platform (4) and the print head (7). Step S3: The motion control module (902) drives the servo motor (11) to rotate according to the motion command, and drives the molding platform (4), the movable frame (6) and the print head (7) to move in their respective directions through the pulley one (12), pulley two (13), belt (14) and connecting block (15); Step S4: During the movement, the laser interferometer (16) detects the spatial position signal of the forming platform (4) in real time, and the grating ruler (17) detects the linear displacement signal of the print head (7) in real time, and sends them to the position closed-loop adjustment module (904) respectively. Step S5: The position closed-loop adjustment module (904) corrects the pulse signal output by the motion control module (902) in real time based on the received spatial position signal and the linear displacement signal to compensate for motion errors; Step S6: The print head (7) prints layer by layer on the forming platform (4) until the three-dimensional object is formed.

9. A printing method for a high-performance 3D printer according to claim 8, characterized in that: In step S3, the speed forward planning module (906) pre-calculates the speed change curves of displacement mechanism one, displacement mechanism two and displacement mechanism three at the inflection point based on the path point coordinates in the file and the preset acceleration / deceleration parameters, and outputs the speed optimization value to the motion control module (902) to suppress the vibration of the print head (7) when turning.

10. A printing method for a high-performance 3D printer according to claim 8, characterized in that: In any of steps S1 to S6, when the material shortage detection module (907) detects a material shortage, it sends a material shortage signal to the main control module (901); or when the temperature control module (903) detects an over-temperature, it sends an over-temperature signal to the main control module (901). After receiving the material shortage signal or the over-temperature signal, the main control module (901) immediately suspends the output of the motion control module (902) and the induction heating drive module (905), and at the same time, the alarm module (908) drives the audible and visual alarm to issue an audible and visual alarm.

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