Metal additive method, device and digital model-based control metal additive method

Abstract

The application relates to a metal additive method, a device and a digital model control metal additive method, which comprises printing a support part and target metal, and the support part is used for providing structural support for a overhanging part of the target metal. In the printing process, the target metal is printed in multiple layers from bottom to top by means of laser wire feeding, and the target metal comprises a directly printable straight-out part and an overhanging part needing support; for the overhanging part, the support part of the corresponding height is first printed, and then the printing of the overhanging part is carried out above the support part; the support part comprises a release part in contact with the target metal, and the release part is made of a material easy to separate from the metal material; after the printing is completed, the target metal is obtained through physical or chemical separation from the target metal; the application provides stable support for the overhanging part through the support part, and meanwhile, the release part easy to separate from the metal material is arranged, so that the support separation treatment process after the printing is simplified, and the printing efficiency and product quality are improved.

Description

Technical Field

[0001] This application relates to the technical field of metal additive manufacturing, and in particular to a metal additive manufacturing method, apparatus, and a metal additive manufacturing method based on digital model control. Background Technology

[0002] Additive manufacturing technology, also known as 3D printing technology, is an emerging manufacturing process that is gradually gaining widespread application. Additive printing creates three-dimensional objects by depositing materials layer by layer. Compared to traditional subtractive manufacturing and equal-material manufacturing, such as milling, turning, casting, and forging, it offers significant advantages, including the ability to quickly manufacture complex-shaped parts, reduce material waste, and shorten product development cycles.

[0003] In the field of metal additive manufacturing, laser filament feeding printing is a commonly used and increasingly mature technology. This method uses a high-energy-density laser beam focused on a substrate or pre-printed structure to form a tiny molten pool. Simultaneously, a metal filament is precisely fed into this pool, where it rapidly melts and fuses with the metal substrate under the influence of laser energy. As the laser beam and filament feeding mechanism move along a pre-planned path, the molten pool advances continuously, and the molten metal gradually solidifies, forming a new metal layer. This process is repeated layer by layer until the desired metal part is manufactured.

[0004] Laser wire feeding technology for printing metal materials has the advantages of high efficiency and high performance. It can directly and quickly form based on a three-dimensional model without the need to manufacture complex molds. Moreover, the high energy density of the laser allows the metal wire to melt and solidify rapidly, resulting in a dense cladding layer with good mechanical properties and metallurgical bonding quality.

[0005] However, when using laser wire feeding technology to print metal parts with overhangs, if there is no suitable support structure, the overhangs will sag, deform, or even fall off due to gravity before they are fully solidified or cooled, resulting in printing failure or unqualified part quality.

[0006] In existing technologies, a metal support structure identical to the target metal is typically printed as a support. After printing, the support structure needs to be removed manually using machining methods such as cutting and grinding. However, this method is not only time-consuming and labor-intensive, but also inefficient. Furthermore, the removal of the support structure can easily damage the target metal, affecting the surface quality and dimensional accuracy of the part. Summary of the Invention

[0007] In view of the shortcomings of the existing technology, the purpose of this application is to provide a metal additive manufacturing method, apparatus and a digital model-controlled metal additive manufacturing method, which can solve the printing problem of overhanging parts and improve the accuracy of the target metal.

[0008] The above-mentioned objective of this application is achieved through the following technical solution:

[0009] A metal additive manufacturing method includes printing a support portion and a target metal, the support portion being used to support the target metal, and the target metal being obtained by physical or chemical separation from the target metal after printing is completed.

[0010] Furthermore, the target metal is printed in multiple layers from bottom to top using a laser wire feeding method.

[0011] Furthermore, the target metal includes a direct printable portion and a suspended portion that requires support from the support portion. Before printing the suspended portion, a support portion of a corresponding height is first formed, and then the suspended portion is printed above it.

[0012] Furthermore, the support portion includes a release portion that contacts the target metal, and the release portion is made of a material that is easy to separate from the metal material.

[0013] As a preferred embodiment of the present invention, the support portion further includes a pressure-bearing portion, and the release portion is connected to the pressure-bearing portion.

[0014] As a preferred embodiment of the present invention, during the printing process of each layer of the overhanging portion, the printing of the lower pressure-bearing portion is completed first, and then one or more release portions below the overhanging portion are printed, with the overhanging portion being printed under the support of the release portions.

[0015] As a preferred embodiment of the present invention, the release portion and the pressure-bearing portion are printed using different materials, while the pressure-bearing portion and the target metal are printed using the same material.

[0016] As a preferred embodiment of the present invention, the support portion is separated by destroying the release portion to obtain the target metal.

[0017] As a preferred embodiment of the present invention, the material of the release portion is selected from one or more of ceramics, polyimide, or fluoroplastics.

[0018] As a preferred embodiment of the present invention, the release portion is printed using one or more of the following methods: fused deposition modeling, direct ink writing technology, or aerosol jet printing.

[0019] An apparatus for metal additive manufacturing, used in the aforementioned metal additive manufacturing method, includes a laser filament feeding printing device, a release part printing device, and a controller, wherein the controller controls the switching between the laser filament feeding printing device and the release part printing device.

[0020] As a preferred embodiment of the present invention, the laser wire feeding printing device and the release part printing device share the same driving device.

[0021] A digital-analog controlled metal additive manufacturing method, and an apparatus for controlling the aforementioned metal additive manufacturing, includes the following steps:

[0022] Step S1: Design a three-dimensional model of the target metal using software, and establish a three-dimensional model of the support part based on the model of the target metal;

[0023] Step S2: The release part is generated at the interface where the support part contacts the target metal, and the release part is generated within the support part;

[0024] Step S3: Slice the model to obtain three slice data types: slice of the target metal, slice of the pressure-bearing part, and slice of the release part. The above three data types are combined to form four types of slices: slice containing only the target metal, slice containing the target metal and the release part, slice containing the target metal and the pressure-bearing part, and slice containing the target metal, the pressure-bearing part, and the release part.

[0025] Step S4: The controller plans the slice forming and printing file based on the data corresponding to the slices in the four cases;

[0026] Step S5: Print layer by layer according to the print file, prioritizing the printing of the target metal in each layer, followed by the printing of the support portion;

[0027] Step S6: After printing is completed, separate the support portion to obtain the target metal.

[0028] In summary, the beneficial technical effects of this application are as follows:

[0029] 1. When printing metal parts with overhangs, this application uses a support to provide stable support for the overhangs, preventing the overhangs from drooping, deforming, or even falling off due to gravity before they are fully solidified or cooled. This significantly reduces the printing failure rate, improves the quality of the parts, and solves the problem of lack of effective support when printing overhangs with laser wire feeding.

[0030] 2. The support part of this application adopts a design that includes a release part, and the release part is made of a material that is easy to separate from the metal material, which makes it easier to separate the support part from the target metal after printing. Compared with traditional machining to remove the support structure, there is no need for complicated cutting, grinding and other operations, which significantly saves post-processing time and labor costs.

[0031] 3. This application removes the support part through physical or chemical separation, avoiding damage to the target metal caused by cutting, grinding and other operations during the removal of the support structure in traditional machining methods. This effectively ensures the surface quality and dimensional accuracy of the parts and improves product quality.

[0032] 4. This application divides the target metal into a straight section and a hanging section, and adopts different printing strategies for different sections. This differentiated printing mode greatly improves the adaptability of metal additive manufacturing to complex structural metal parts, can flexibly meet various design requirements, and breaks through the limitations of traditional printing technology in terms of structural complexity.

[0033] 5. Compared to traditional methods that require high-precision cutting and grinding equipment to remove the support structure, this technical solution simplifies the post-processing workflow, thereby reducing reliance on and requirements for post-processing equipment. Reduced equipment usage frequency decreases wear and tear, thus lowering maintenance costs and the risk of production stoppages due to equipment failure. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the target metal.

[0035] Figure 2 This is a schematic diagram showing how a release liner is used to support the target metal.

[0036] Figure 3 This is a schematic diagram showing the separation of the target metal and the pressure-bearing part using a release liner.

[0037] Figure 4 A schematic diagram of printing a target metal with a complex structure.

[0038] Figure 5 This is a schematic diagram of a printing method for a multi-layered overhanging section of target metal.

[0039] Figure 6 This is a schematic diagram of another printing method for the target metal of a multi-layered overhang.

[0040] Figure 7 for Figure 3 A schematic diagram of the front view.

[0041] Figure 8 for Figure 7 A schematic diagram of the cross-sectional view at point AA.

[0042] Figure 9 for Figure 7 A schematic diagram of the cross-sectional view at point BB.

[0043] Figure 10 This is a front view schematic diagram showing a gap between the straight section and the support section.

[0044] Figure 11 for Figure 10 A schematic diagram of the cross-sectional view at point CC.

[0045] Figure 12 for Figure 10 A schematic diagram of the cross-sectional view at point DD.

[0046] Explanation of the reference numerals: 1. Target metal; 11. Straight part; 12. Overhanging part; 2. Support part; 21. Release part; 22. Pressure bearing part; 3. Gap. Detailed Implementation

[0047] The present application will be further described in detail below with reference to the accompanying drawings.

[0048] like Figure 1 As shown, a target metal 1 with a cantilever portion 12 is illustrated. This target metal 1 is deposited layer by layer from bottom to top using laser filament feeding, and the structure is constructed in multiple layers sequentially. The target metal 1 includes a directly printable output portion 11 and a cantilever portion 12 that requires support from a support portion 2. Because the cantilever portion 12 lacks direct support during the printing process, and the metal material cannot resist the influence of gravity during the liquid to solidification stage, when printing reaches the cantilever portion 12, without external support, the undone metal will shift downwards due to gravity, causing deformation of the formed structure. In severe cases, the cantilever portion 12 may detach from the main body, disrupting the printing continuity and causing printing failure. Therefore, it is necessary to construct a suitable support portion 2 to ensure the smooth progress of the printing process and achieve the required forming accuracy, thus realizing the printing of a complete and high-quality target metal 1.

[0049] A metal additive manufacturing method includes a printing support 2 and a target metal 1, wherein the support 2 is used to support the target metal 1, and the target metal 1 is obtained by physical or chemical separation from the target metal 1 after printing is completed.

[0050] Example 1:

[0051] like Figure 2 As shown, when printing the overhang 12, a support part 2 of the corresponding height is first formed, and then the overhang 12 is printed above it; the support part 2 adopts a release part 21, which contacts the target metal 1, and the release part 21 is made of a material that is easy to separate from the metal material.

[0052] It is worth noting that the release part 21 has good thermal stability and can withstand the heat load during the laser wire feeding process.

[0053] Preferably, the release part 21 can be easily removed after printing by mechanical tapping. Specifically, mechanical tapping is a relatively simple separation method. Since the release part 21 is made of a material that easily separates from metal and has good thermal stability, it will not form a strong metallurgical bond with the target metal 1 during the high-temperature process of laser filament printing. Therefore, the target metal 1 can be obtained by tapping to destroy part or all of the release part 21. During the tapping operation, a tapping tool of appropriate weight and shape, such as a rubber mallet or wooden mallet, is selected. The edge where the release part 21 connects to the target metal 1 is gently tapped. The force generated by the vibration breaks the weak adhesion between the two, achieving separation of the release part 21 from the target metal 1. The advantage of this method is its ease of operation, requiring no additional complex equipment, and low cost. It is suitable for parts with relatively simple structures and where surface quality requirements are not extremely high.

[0054] Preferably, the part can be easily removed after printing by heating. Specifically, given the good thermal stability of the release part 21, the printed part can be placed as a whole into a heating device, such as an industrial oven, for heating separation. A suitable heating temperature is set based on the material properties of the release part 21. As the temperature rises, the bonding force between the release part 21 and the target metal 1 gradually weakens due to the difference in their coefficients of thermal expansion. When a certain temperature is reached, a noticeable gap 3 appears between the release part 21 and the target metal 1. At this point, only a light external force is needed to separate the release part 21 from the target metal 1. The advantage of the heating separation method is that it causes less damage to the overall part and is suitable for metal parts with high requirements for dimensional accuracy and surface quality.

[0055] Preferably, the part can be easily removed after printing via chemical immersion. Specifically, based on the chemical properties of the release part 21 material, a chemical reagent that reacts specifically with it but not with the target metal 1 is selected. The printed part is then immersed in a prepared chemical solution. Under the action of the chemical reaction, the release part 21 material is gradually dissolved or undergoes structural changes, weakening its connection with the target metal 1, ultimately achieving separation. During the immersion process, the chemical reaction can be accelerated and the separation time shortened by stirring the solution or appropriately increasing the temperature. The advantage of the chemical immersion method is that it can penetrate deep into the interior of complex structures, achieving comprehensive separation, and is particularly suitable for parts with complex structures that are difficult to separate by other methods.

[0056] Preferably, the release liner 21 may be made of one or more of ceramic matrix composites, oxide-metal composites, or surface-treated peelable coatings, polyimide, or fluoroplastics. The release liner 21 may be printed using one or more of fused deposition modeling, direct ink writing technology, or aerosol jet printing.

[0057] Specifically, the release part 21 is a ceramic composite material containing yttrium-stabilized zirconia (YSZ), and the difference in the coefficient of thermal expansion between it and the target metal 1 enhances the self-peeling ability after printing.

[0058] More specifically, the release part 21 made of ceramic matrix composite material is used as an example for illustration. Since ceramic matrix composite material has the characteristics of high hardness, high temperature resistance and good chemical stability, when designing the removal method, its characteristics should be fully utilized and combined with the characteristics of the target metal 1. The shape and structure of the target metal 1 and the support part 2 should also be taken into consideration.

[0059] The target metal 1 is obtained by mechanical hammering, with only a weak physical adhesion between the release part 21 of the ceramic matrix composite and the target metal 1. Copper or wooden hammering tools can be used. Copper tools are relatively soft and less likely to scratch the target metal 1; wooden tools are lighter and provide a gentler impact. During operation, the weak points in the connection between the release part 21 and the target metal 1 are first identified through observation and analysis. Then, the hammering tool is used to strike along these weak points with appropriate force and frequency, ensuring the strikes are on the release part 21 to avoid damaging the target metal 1. The vibration generated by the hammering gradually breaks down the adhesion between the release part 21 and the target metal 1, causing the release part 21 to loosen and eventually separate from the target metal 1. This method is suitable for metal parts with relatively simple structures and less stringent surface roughness requirements because it is simple to operate, inexpensive, and allows for rapid removal of the release part 21.

[0060] The target metal 1 is obtained through heating separation, taking advantage of the significant difference in thermal expansion coefficients between the ceramic matrix composite and the metal. During heating separation, the metal part with the release part 21 is placed in a high-temperature furnace. Based on the thermal expansion characteristics of the ceramic matrix composite and the target metal 1, the heating temperature and heating rate are precisely set. As the temperature gradually increases, stress is generated between the release part 21 of the ceramic matrix composite and the target metal 1 due to the difference in thermal expansion. When the temperature reaches a certain level, the stress causes a gap 3 to appear at the interface between the release part 21 and the target metal 1. At this point, heating is stopped, and after the part cools to a suitable temperature, a gentle external force is applied to separate the release part 21 from the target metal 1. This method causes minimal damage to the part and is suitable for metal parts requiring high dimensional accuracy and surface quality, especially for parts with complex shapes that are difficult to separate mechanically.

[0061] The target metal 1 is obtained through chemical immersion. A chemical reagent that reacts with the ceramic matrix composite material but not with the target metal 1 is selected, such as a hydrofluoric acid solution of a specific concentration, specifically for silicon-containing ceramic matrix composites. The printed part is completely immersed in the chemical solution, which reacts with the release portion 21 of the ceramic matrix composite material, causing it to gradually dissolve or decompose. During immersion, to accelerate the reaction, a magnetic stirrer can be used to agitate the solution, or the solution temperature can be appropriately increased by heating in a water bath. As the reaction continues, the connection between the release portion 21 and the target metal 1 is gradually broken down, ultimately achieving separation. This method is suitable for metal parts with complex internal structures and can reach various parts of the part to remove the release portion 21.

[0062] In this embodiment, a support portion 2 of corresponding height is constructed before printing the overhang portion 12. This effectively solves the problems of sagging, deformation, and detachment of the overhang portion 12 due to gravity during the printing process, significantly improving the printing success rate of metal parts with the overhang portion 12 and broadening the application scope of laser wire feeding printing technology. The release portion 21 is made of a material that is easy to separate from the metal material and has good thermal stability, avoiding strong metallurgical bonding with the target metal 1 under the high temperature environment of laser wire feeding printing, fundamentally reducing the difficulty of post-processing.

[0063] Example 2:

[0064] like Figure 3 As shown, when printing the overhang 12, a support 2 of corresponding height is first formed, and then the overhang 12 is printed above it; the support 2 includes a pressure-bearing part 22 and a release part 21. The release part 21 is connected to the pressure-bearing part 22. The release part 21 is only provided in the part that contacts the target metal 1, and separates the target metal 1 and the pressure-bearing part 22 in the form of an interface or layer.

[0065] It is worth noting that the release part 21 has good thermal stability and can withstand the heat load during the laser wire feeding process. Furthermore, during the printing process, the release part 21 and the target metal 1 form a weak metallurgical bond or non-metallurgical bond interface at the printing temperature.

[0066] In this embodiment, the pressure-bearing part 22 undertakes the main supporting role, providing stable support for the hanging part 12. Compared with the single-structure support part 2, this design that separates the support and release functions makes the support structure more reasonable. The pressure-bearing part 22 can be made of high-strength and high-stability materials to ensure that it can withstand the weight of the hanging part 12 during the printing process, avoiding printing failure due to insufficient support and improving the stability of the printing process.

[0067] Release section 21 separates the target metal 1 and the pressure-bearing section 22 in the form of an interface or layer, further enhancing the release effect. After printing, the support section 2 can be easily removed by simply separating the release section 21 from the target metal 1 and the pressure-bearing section 22. Compared with the traditional integral support structure, this greatly simplifies the post-processing process, shortens the post-processing time, and improves production efficiency.

[0068] In this embodiment, for the overhanging part 12 with different shapes and weights, the pressure-bearing part 22 material with different strengths can be selected; for different types of target metal 1, the release part 21 material with different properties can be selected, thereby improving the flexibility and adaptability of the entire metal additive manufacturing process and meeting diverse production needs.

[0069] Furthermore, using the same material for both the target metal 1 and the pressure-bearing part 22 reduces equipment investment and maintenance costs. In metal additive manufacturing, if the target metal 1 and the pressure-bearing part 22 were made of different materials, along with the release liner 21, three independent printing units would be required to separately deliver and form different materials. Using the same material for both reduces the purchase cost of the printing units. In addition, the reduced number of devices lowers the workload for daily maintenance, calibration, and troubleshooting, saving on equipment maintenance costs and time.

[0070] Using the same material avoids the need for complex adjustments and switching of key parameters such as laser power, filament feed speed, and printing temperature due to differences in material properties. A single set of parameters can meet the needs of the entire printing process. This not only reduces the complexity of the printing process but also reduces printing defects caused by improper parameter settings, improves printing stability and success rate, significantly shortens pre-printing preparation time, and accelerates the production pace.

[0071] The target metal 1 and the pressure-bearing part 22 are made of the same material and have the same physical and chemical properties. This helps to ensure that the target metal 1 and the pressure-bearing part 22 exhibit consistent performance in terms of load bearing, deformation resistance, and thermal effects. For example, when subjected to high temperatures and external forces, their coefficients of thermal expansion are the same, enabling them to deform in tandem and avoid problems such as stress concentration and connection failure caused by differences in material properties, thereby improving the stability and reliability of the entire structure.

[0072] In this embodiment, since the release part 21 is disposed between the target metal 1 and the pressure-bearing part 22 in the form of an interface or layer, a relatively weak separation interface is formed. When mechanical impact is used, this interface is more easily damaged, thereby achieving separation between the two. Compared with a structure without this design, it can effectively avoid damage such as deformation and cracks to the target metal 1 caused by excessive or uneven mechanical impact force, thus better ensuring the integrity and performance of the target metal 1.

[0073] Because the separation interface is clearly defined and relatively fragile, force is more easily concentrated on this interface during mechanical hammering, making the separation process more efficient. Unlike dealing with traditional monolithic support structures, it eliminates the need to spend considerable time and effort finding suitable hammering points and controlling hammering force, thus improving the efficiency of post-processing.

[0074] In this embodiment, the release part 21 separates the target metal 1 and the pressure-bearing part 22. When separated by heating, the expansion difference caused by the heat change is mainly concentrated in the release part 21 and its surrounding area. The target metal 1 and the pressure-bearing part 22 damage the release part 21 from both sides, making it easier to separate.

[0075] In this embodiment, the release part 21 serves as an isolation layer. Its small size allows for rapid removal, resulting in shorter chemical soaking time, better separation effect, and reduced usage of chemical soaking solution and processing costs.

[0076] Example 3:

[0077] like Figure 4 As shown, when printing the overhang 12, a support part 2 of the corresponding height is first formed, and then the overhang 12 is printed above it; the support part 2 adopts a release part 21, which contacts the target metal 1, and the release part 21 is made of a material that is easy to separate from the metal material.

[0078] In this embodiment, given the complexity of the printed structure, after printing is completed, the separation of the support part 2 from the target metal 1 is mainly achieved by two methods: heating separation and chemical immersion.

[0079] In this embodiment, a printing method is provided for complex structures that require support. The complex shape contains multiple overhanging structures, which are prone to deformation due to gravity during the printing process. By printing the support part 2 of the corresponding height first, a stable support is provided for the overhanging part 12 of the complex structure. This ensures that during the printing process, the molten metal material can solidify and form according to the preset path with the assistance of the support, effectively avoiding printing failures caused by insufficient support and greatly improving the printing success rate of complex metal parts.

[0080] Example 4:

[0081] When the target metal 1 has multiple or multiple layers of overhanging parts 12, a corresponding support part 2 is printed below each overhanging part 12. Preferably, the support part 2 is printed using the lower layer of overhanging parts 12 as a support, and then the upper layer of overhanging parts 12 is printed on the basis of the support part 2 that has just been printed.

[0082] Preferably, such as Figure 5As shown, the support between the two overhanging portions 12 is formed by completely filling the release portion 21; more preferably, as shown in the figure Figure 6 As shown, the support portion 2 of the two suspension portions 12 adopts a combination of release portion 21 and pressure-bearing portion 22. The release portion 21 is only provided in the part that contacts the target metal 1, and the target metal 1 and the pressure-bearing portion 22 are separated in the form of interface or layer. The pressure-bearing portion 22 located between the suspension portions 12 is connected to the pressure-bearing portion 22 below, so that the subsequent removal operation of the support portion 2 is more convenient.

[0083] A metal additive manufacturing apparatus for implementing the above-described metal additive manufacturing method includes a laser filament feeding printing device, a release section 21 printing device, and a controller, wherein the controller controls the switching between the laser filament feeding printing device and the release section 21 printing device.

[0084] Furthermore, the release part 21 printing device is used to print the release part 21. Preferably, the release part 21 printing device can be the ceramic 3D printing extrusion nozzle in the Chinese utility model patent with publication number CN206937549U.

[0085] Furthermore, switching between uses means that during the metal additive manufacturing process, when the target metal 1 structure needs to be printed, the controller sends a command to the laser filament feeding printing device to start the device. The laser filament feeding printing device, following a predetermined printing path, uses laser energy to melt the metal filament and deposit it layer by layer to construct the main structure of the target metal 1. When printing reaches the position where the release part 21 needs to be set, the controller pauses the operation of the laser filament feeding printing device and quickly sends a start signal to the release part 21 printing device. The release part 21 printing device then begins to work. Taking the ceramic 3D printing extrusion nozzle described in Chinese Utility Model Patent Publication No. CN206937549U as an example, this nozzle extrudes the release material according to pre-set parameters and path and precisely lays it in the corresponding position to form the release part 21. After the release section 21 is printed, the controller switches again and restarts the laser filament feeding printing device to continue printing the subsequent structure of the target metal 1. This cycle repeats. By controlling the precise switching between the laser filament feeding printing device and the release section 21 printing device, the process of alternating printing of the target metal 1 and the release section 21 in the metal additive manufacturing method is realized, ensuring the smooth progress of the entire metal additive manufacturing process and producing a product structure that meets the design requirements.

[0086] Furthermore, the laser filament feeding printing device and the release section 21 printing device share the same drive unit. This design greatly optimizes the structure and operation mechanism of the metal additive manufacturing device. The same drive unit can be a three-axis drive mechanism or a robotic arm, etc. Preferably, the end of the drive unit includes a turntable, on which both the laser filament feeding printing device and the release section 21 printing device are mounted. The rotation of the turntable ensures that the filament feeding printing device, the release section 21 printing device, and the printed section do not interfere with each other.

[0087] When the metal additive manufacturing process begins, if the target metal 1 needs to be printed, the drive unit, according to the instructions issued by the controller, manipulates the turntable to rotate, precisely positioning the laser filament feeding printing device to the working position. At this time, the three-axis drive mechanism or robotic arm works in concert to drive the laser filament feeding printing device to move precisely in the X, Y, and Z axes, while controlling the laser emission and the delivery of the metal filament, completing the layer-by-layer deposition of the target metal 1 according to the preset path.

[0088] When the release section 21 needs to be printed, the drive unit activates again, rotating the turntable to move the laser filament feeding printing device out of the working area and simultaneously switching the release section 21 printing device to the working position. Then, the drive unit manipulates the release section 21 printing device to move along the corresponding axis, completing the extrusion and laying of the release material. Throughout the printing process, as the number of printed layers increases, the height of the printed section gradually increases. The rotation of the turntable allows for flexible adjustment of the positions of the laser filament feeding printing device and the release section 21 printing device, ensuring that they do not collide or interfere with the already printed section during operation and switching. This guarantees the continuous, stable, and efficient execution of the metal additive manufacturing process, greatly improving printing efficiency and product quality.

[0089] A digital-analog controlled metal additive manufacturing method, and an apparatus for controlling the aforementioned metal additive manufacturing, includes the following steps:

[0090] Step S1: Model the target metal 1 using software, and establish the support part 2 based on the model of the target metal 1;

[0091] Step S2: A release part 21 is generated at the interface where the support part 2 contacts the target metal 1. The release part 21 is generated inside the support part 2.

[0092] Step S3: Slice the model to obtain slices of target metal 1, pressure-bearing part 22 and release part 21 of three slice data types. The above three data combinations form four types of slices, namely target metal 1, target metal 1 and release part 21, target metal 1 and pressure-bearing part 22, and target metal 1, pressure-bearing part 22 and release part 21.

[0093] Step S4: The controller plans the slice forming and printing file according to the slice data of the four cases.

[0094] Step S5: Print the target metal 1 layer by layer, followed by the support part 2.

[0095] Step S6: Separate the support part 2 to obtain the target metal 1.

[0096] In step S3, it is necessary to explain four cases, such as... Figures 7-12 As shown, specifically, in printing Figure 7 When the overhanging part 12 is in the middle, only the target metal 1 exists in the printed layer, which belongs to the first type of slicing case; Figure 8 and Figure 11 In the printed layer, there are target metal 1 and release part 21, which belongs to the second type of slicing case; Figure 9 In the printed layer, there are target metal 1, release part 21 and pressure-bearing part 22, which belongs to the third type of slicing case; Figure 12 In the printed layer, there are target metal 1 and pressure-bearing part 22, which belongs to the fourth type of slicing.

[0097] Specifically, it should be noted that... (See also) Figure 10 In the case where there is a gap 3 between the target metal 1 and the support 2, the pressure-bearing part 22 serves as a support, and the release part 21 exists only between the hanging part 12 and the support 2. Figure 10 Below the central overhang 12.

[0098] In step S5, it should be noted that during the printing process of each layer of the hanging part 12, the printing of the lower pressure-bearing part 22 is completed first, and then the release part 21 of one or more layers below the hanging part 12 is printed. The hanging part 12 of that layer is printed under the support of the release part 21 of one or more layers below.

[0099] The embodiments described in this specific implementation are preferred embodiments of this application and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A metal additive manufacturing method, characterized in that, The method includes printing a support part (2) and a target metal (1), wherein the support part (2) is used to support the target metal (1), and after printing is completed, the target metal (1) is obtained by physical or chemical separation from the target metal (1); The target metal (1) is printed in multiple layers from bottom to top using a laser wire feeding method; The target metal (1) includes a direct output part (11) that can be printed directly and a hanging part (12) that needs to be supported by the support part (2). Before printing the hanging part (12), the support part (2) of the corresponding height is formed first, and then the hanging part (12) is printed above it. The support portion (2) includes a release portion (21) that contacts the target metal (1), the release portion (21) being made of a material that is easy to separate from the metal material.

2. The metal additive manufacturing method according to claim 1, characterized in that, The support part (2) also includes a pressure-bearing part (22), and the release part (21) is connected to the pressure-bearing part (22).

3. The metal additive manufacturing method according to claim 2, characterized in that, During the printing process of each layer of the overhang (12), the printing of the lower pressure-bearing part (22) is completed first, and then the release part (21) below the overhang (12) is printed one or more layers below it. The overhang (12) of that layer is printed under the support of the release part (21).

4. The metal additive manufacturing method according to claim 2, characterized in that, The release part (21) and the pressure-bearing part (22) are printed using different materials, while the pressure-bearing part (22) and the target metal (1) are printed using the same material.

5. The metal additive manufacturing method according to claim 1, characterized in that, The support portion (2) is separated by destroying the release portion (21) to obtain the target metal (1).

6. The metal additive manufacturing method according to claim 1, characterized in that, The material of the release part (21) is selected from one or more of ceramics, polyimide or fluoroplastics.

7. The metal additive manufacturing method according to claim 1, characterized in that, The release part (21) is printed using one or more of the following methods: fused deposition modeling, direct ink writing technology, or aerosol jet printing.

8. A metal additive manufacturing apparatus for implementing the metal additive manufacturing method according to any one of claims 1-7, characterized in that, It includes a laser filament feeding printing device, a release part (21) printing device, and a controller, wherein the controller controls the switching between the laser filament feeding printing device and the release part (21) printing device.

9. The metal additive manufacturing apparatus according to claim 8, characterized in that, The laser wire feeding printing device and the release part (21) printing device share the same driving device.

10. A method for controlling metal additive manufacturing based on digital model control, and an apparatus for manipulating the metal additive manufacturing process of claim 8, characterized in that, Includes the following steps: Step S1: Use software to design a three-dimensional model of the target metal (1), and establish a three-dimensional model of the support part (2) based on the model of the target metal (1); Step S2, the release part (21) is generated at the interface where the support part (2) contacts the target metal (1), and the release part (21) is generated inside the support part (2); Step S3: Slice the model to obtain slices of the target metal (1), the pressure-bearing part (22), and the release part (21) of three different slice data types. The above three data types are combined to form four types of slices: slices containing only the target metal (1), slices containing the target metal (1) and the release part (21), slices containing the target metal (1) and the pressure-bearing part (22), and slices containing the target metal (1), the pressure-bearing part (22), and the release part (21). Step S4: The controller plans the slice forming and printing file based on the data corresponding to the slices in the four cases; Step S5: Print layer by layer according to the print file, with the target metal (1) printed first in each layer, followed by the support part (2); Step S6: After printing is completed, the support part (2) is separated to obtain the target metal (1).

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