Top-down-type high-viscosity 3D printing device and 3D printing method thereof

Abstract

Disclosed are a top-down-type high-viscosity 3D printing device and a 3D printing method thereof, wherein multiple layers are formed by curing a high viscosity photocurable resin coated on a coating area of the lower surface of a support film by using light emitted from a light source in a state in which the high viscosity photocurable resin is positioned and aligned on a build plate part by a horizontal reciprocating motion using one recoating roller and two release rollers positioned on both sides spaced apart from the recoating roller.

Description

Top-down high-viscosity 3D printing device and 3D printing method thereof

[0001] The present invention relates to a top-down high-viscosity 3D printing device and a 3D printing method thereof, and more particularly, to a top-down high-viscosity 3D printing device and a 3D printing method thereof, which forms a plurality of building layers by curing a high-viscosity photocurable resin coated on a coating area on the lower surface of a support film using a recoating roller and two shaping rollers positioned on either side spaced apart from the recoating roller while positioning the high-viscosity photocurable resin on a building plate portion using a horizontal reciprocating motion, using light irradiated from a light source.

[0002]

[0003] In general, 3D printing methods include the SLA (StereoLithography Apparatus) method, which uses the principle of hardening the irradiated area by irradiating laser light on photocurable resin; the DLP (Digital Light Processing) method, which uses a projector to irradiate light on the bottom of a storage tank where photocurable resin is stored; and the FDM (Fused Deposition Modeling) method, which extrudes a filament to layer a structure.

[0004] Among these, the 3D printing methods of SLA and DLP project an ultraviolet light source (laser, projector, LCD, etc.) into a vat containing photocurable liquid resin, and each time the model in the vat of the modeling box is created one layer at a time, the vat rises or falls by the thickness of the layer and the ultraviolet light source is injected again to create the model.

[0005] These SLA and DLP 3D printing technologies have the advantages of high precision and excellent surface roughness of the model, making them the most widely used technologies with medium modeling speed.

[0006] However, conventional SLA and DLP 3D printing photocurable resins primarily used low-viscosity photocurable resins for ease of process. Thus, objects manufactured using low-viscosity photocurable resins had weak mechanical properties, such as strength and hardness, and were prone to deformation at temperatures above approximately 60°C. Furthermore, while the heat distortion temperature could be increased, this trade-off resulted in reduced tensile and flexural strength.

[0007] Therefore, efforts are being made recently to use high-viscosity photocurable resins with increased molecular weight or high-viscosity photocurable resins with increased viscosity of approximately 10,000 cps or more by adding a large amount of ceramic or metal particles in order to improve mechanical properties such as strength and hardness.

[0008] However, when modeling using a high-viscosity photocurable resin with a high molecular weight in the DLP (bottom-up) method, the tank rises vertically by the layer thickness each time the model is created one layer at a time. Afterwards, when scanning with an ultraviolet light source (laser, projector, LCD, etc.), if each modeling layer is separated vertically while the high-viscosity photocurable resin is cured, excessive stress causes each modeling layer to separate, or cracks occur in each modeling layer, resulting in defects.

[0009] In addition, when modeling using high-viscosity photocurable resin with high molecular weight in the SLA (top-down) method, the build plate must be lowered vertically by the layer thickness each time the model is created, and the cured top surface must be recoated (a process of covering it with photocurable resin). However, in this case, there was the problem that it was difficult to match the resin level due to the high viscosity, and it took a long time to match the resin level.

[0010] Therefore, there is an urgent need to develop a new type of 3D printer for manufacturing objects using high-viscosity photocurable resins with excellent mechanical properties.

[0011] A related prior art document is Korean Patent Publication No. 10-2286444 (published on August 4, 2021), which describes a 3D printing method, a soft sensor manufactured therefrom, and its use.

[0012]

[0013] The purpose of the present invention is to provide a top-down high-viscosity 3D printing device and a 3D printing method thereof, which forms a plurality of building layers by curing a high-viscosity photocurable resin coated on a coating area on the lower surface of a support film using a horizontal reciprocating motion using one recoating roller and two release rollers positioned on both sides spaced from the recoating roller while aligning the high-viscosity photocurable resin on a building plate section using light irradiated from a light source.

[0014]

[0015] According to an embodiment of the present invention for achieving the above object, a top-down high-viscosity 3D printing device comprises: a resin storage tank filled with a high-viscosity photocurable resin; a support film disposed on an upper side spaced apart from the resin storage tank; a recoating roller, one of which is disposed between the resin storage tank and the support film to support a lower surface of the support film and to coat a high-viscosity photocurable resin in the resin storage tank on a coating area of ​​the support film; two release rollers, two of which are mounted on both sides spaced apart from the recoating roller on the upper surface of the support film, to release the high-viscosity photocurable resin that has been hardened after being coated on the coating area of ​​the support film; a forming plate, which is mounted on one side spaced apart from the resin storage tank, the recoating roller, and the release roller, and to laminate the high-viscosity photocurable resin coated on the coating area of ​​the lower surface of the support film when the recoating roller and the release roller are moved in a horizontal reciprocating motion; And it is characterized by including a light source unit mounted on an upper portion spaced apart from the above-mentioned forming plate portion, for irradiating light onto the high-viscosity photocurable resin positioned on the above-mentioned forming plate portion to harden the high-viscosity photocurable resin to form a plurality of forming layers.

[0016] The above high viscosity photocurable resin has a viscosity of 10,000 to 800,000 cps.

[0017] The above recoating roller is mounted so that its lower part is inserted into the resin storage tank and is immersed in the high viscosity photocurable resin filled in the resin storage tank, and its upper part is mounted so that it comes into contact with the lower surface of the support film and supports the support film.

[0018] The above recoating roller is mounted in one unit within the resin storage tank, and the release roller is mounted in two units, including a first release roller mounted on one side of the upper surface of the support film and a second release roller mounted on the other side opposite to the one side of the upper surface of the support film.

[0019] When the recoating roller is rotated in the first direction, the release roller is rotated in a second direction opposite to the first direction to horizontally move the recoating roller and the release roller in one direction, and when the recoating roller is rotated in the second direction, the release roller is rotated in the first direction opposite to the second direction to horizontally move the recoating roller and the release roller in the other direction opposite to one side.

[0020] The above 3D printing device further includes a bracket unit mounted on both edges of the recoating roller and the release roller to fix the drive shaft of the recoating roller and the drive shaft of the release roller to each other; and a resin storage tank for supplying a high-viscosity photocurable resin into the resin storage tank through a resin supply pipe connected to the resin storage tank.

[0021] When the high-viscosity photocurable resin coated on the coating area on the lower surface of the support film is cured by light irradiation from the light source unit, the above-mentioned molding plate section is lowered vertically by the amount of the laminated thickness of the cured high-viscosity photocurable resin.

[0022]

[0023] In order to achieve the above object, a top-down high-viscosity 3D printing method according to an embodiment of the present invention is characterized by including: (a) a step of coating a high-viscosity photocurable resin in a resin storage tank onto a coating area on the lower surface of a support film by horizontally moving one recoating roller positioned on the upper portion of a building plate portion and two release rollers mounted on both sides spaced apart from the recoating roller in one direction; (b) a step of irradiating light onto the high-viscosity photocurable resin positioned on the building plate portion using a light source unit mounted on the upper portion spaced apart from the building plate portion to harden the high-viscosity photocurable resin; and (c) a step of releasing the cured high-viscosity photocurable resin using the release roller while vertically lowering the building plate portion by a thickness of a laminate of the cured high-viscosity photocurable resin to form a building layer.

[0024] In the above step (a), the high viscosity photocurable resin has a viscosity of 10,000 to 800,000 cps.

[0025] In the above step (a), one of the recoating rollers is mounted in the resin storage tank, and two of the release rollers are mounted, including a first release roller mounted on one side of the upper surface of the support film and a second release roller mounted on the other side opposite to one side of the upper surface of the support film.

[0026] After the step (c), (d) a step of coating a high-viscosity photocurable resin in a resin storage tank onto a coating area on the lower surface of a support film using the recoating roller while horizontally moving one recoating roller positioned on the upper portion of the forming plate portion and two release rollers mounted on both sides spaced apart from the recoating roller in the opposite direction to one direction; (e) a step of curing the high-viscosity photocurable resin positioned on the forming plate portion by irradiating light using a light source unit mounted on the upper portion spaced apart from the forming plate portion; and (f) a step of releasing the cured high-viscosity photocurable resin using the release roller while vertically lowering the forming plate portion by a thickness of the laminated high-viscosity photocurable resin to form a forming layer.

[0027]

[0028] A top-down high-viscosity 3D printing device and a 3D printing method according to the present invention coat a high-viscosity photocurable resin on the lower surface of a support film by immersing one recoating roller in a high-viscosity photocurable resin with a high molecular weight filled in a resin storage tank and pulling it up with one recoating roller, and then curing it with a light source unit and minimizing the force required for releasing through a release roller to form a plurality of modeling layers, thereby significantly improving the mechanical properties of the plurality of modeling layers and minimizing the amount of high-viscosity photocurable resin used.

[0029] As a result, the top-down high-viscosity 3D printing device and 3D printing method according to the present invention can selectively perform photocuring only on the high-viscosity photocurable resin coated on the lower surface of the support film without irradiating the high-viscosity photocurable resin in the resin storage tank with light, thereby preventing discoloration of the high-viscosity photocurable resin due to unnecessary photocuring.

[0030] In addition, the top-down high-viscosity 3D printing device and the 3D printing method according to the present invention are a method of photo-curing a high-viscosity photo-curable resin coated on the lower surface of a support film, and then lowering the forming plate section in the vertical direction by the thickness of the high-viscosity photo-curable resin to release the mold, so that layer thickness control for a plurality of forming layers laminated on the forming plate section can be enabled.

[0031] In this way, the top-down high-viscosity 3D printing device and 3D printing method according to the present invention are such that the cured high-viscosity photocurable resin is lowered vertically by the layer thickness through the lowering of the molding plate section each time a plurality of molding layers are created, so not only is there no need to adjust the level of the resin storage tank, but work such as recoating the cured high-viscosity photocurable resin is unnecessary, so there is an effect of greatly improving the process yield.

[0032]

[0033] Figures 1 and 2 are schematic diagrams showing a top-down high-viscosity 3D printing device according to an embodiment of the present invention.

[0034] Figures 3 and 4 are cross-sectional views for explaining the operating principle of moving the recoating roller and the different-shaped roller of the present invention in one direction.

[0035] Figures 5 and 6 are cross-sectional views for explaining the operating principle of moving the recoating roller and the different-shaped roller of the present invention in the opposite direction.

[0036] Figure 7 is a schematic diagram showing the recoating roller and the special roller of the present invention in more detail.

[0037] Fig. 8 is a plan view for explaining the operating principle of the recoating roller of the present invention.

[0038] Figures 9 and 10 are schematic diagrams showing a top-down high-viscosity 3D printing device according to a modified example of the present invention.

[0039] Figures 11 to 14 are process schematic diagrams for explaining a top-down high-viscosity 3D printing method according to an embodiment of the present invention.

[0040]

[0041] The advantages and features of the present invention, and the methods for achieving them, will become clearer with reference to the embodiments described in detail below together with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below, but may be implemented in various different forms. These embodiments are provided only to ensure that the disclosure of the present invention is complete and to fully inform those skilled in the art of the scope of the invention, and the present invention is defined only by the scope of the claims. Like reference numerals designate like elements throughout the specification.

[0042] Hereinafter, with reference to the attached drawings, a top-down high-viscosity 3D printing device and a 3D printing method thereof according to a preferred embodiment of the present invention will be described in detail.

[0043]

[0044] FIG. 1 and FIG. 2 are schematic diagrams showing a top-down high-viscosity 3D printing device according to an embodiment of the present invention.

[0045] Referring to FIGS. 1 and 2, a top-down high-viscosity 3D printing device (100) according to an embodiment of the present invention includes a resin storage tank (110), a support film (120), a recoating roller (130), a release roller (140), a forming plate section (150), and a light source unit (160).

[0046]

[0047] The resin storage tank (110) may have a rectangular parallelepiped shape with an empty space inside, but this is merely an example and it will be obvious that the shape can be applied in various ways. The resin storage tank (110) may be formed of a transparent polymer material, but is not limited thereto.

[0048] The internal empty space of the resin storage tank (110) is filled with a high-viscosity photocurable resin (5). The high-viscosity photocurable resin (5) may have a viscosity of 10,000 to 800,000 cps, a more preferable range may be 100,000 to 600,000 cps, and a most preferable range may be 200,000 to 500,000 cps. When a plurality of molding layers (10) are formed by molding using the high-viscosity photocurable resin (5), the mechanical properties such as strength and rigidity can be greatly improved.

[0049]

[0050] The support film (120) is placed on the upper portion, spaced apart from the resin storage tank (110). It is preferable that the support film (120) be made of a transparent polymer material that allows light irradiated from the light source unit (160) to easily pass through and has excellent strength and rigidity. To this end, the support film (120) may include any one selected from among an FEP film (fluorinated ethylene propylene), a PFA film (perfluoroalkoxy film), a PTFE film (polytetrafluoroethylene film), and an ACF film (anisotropic conductive film), and among these, it is more preferable to use an FEP film.

[0051] It is preferable to use a support film (120) having a thickness of 200 μm or less, because a thickness of 200 μm or less ensures high transmittance while also ensuring sufficient durability.

[0052]

[0053] A recoating roller (130) is placed between the resin storage tank (110) and the support film (120), supports the lower surface of the support film (120), and serves to coat the high viscosity photocurable resin (5) in the resin storage tank (110) on the coating area of ​​the support film (120).

[0054] The recoating roller (130) is mounted so that its lower part is inserted into the resin storage tank (110) and is immersed in the high viscosity photocurable resin (5) filled in the resin storage tank (110), and its upper part is mounted so that it comes into contact with the lower surface of the support film (120) and supports the support film (120).

[0055] One such recoating roller (130) is mounted in the resin storage tank (110). In this way, the present invention coats the lower surface of the support film (120) with the high-viscosity photocurable resin (5) by immersing one recoating roller (130) in the high-viscosity photocurable resin (5) with a high molecular weight filled in the resin storage tank (110) and pulling it up with one recoating roller (130). Therefore, it becomes possible to minimize the amount of the high-viscosity photocurable resin (5) used.

[0056] In addition, since the present invention forms each forming layer (10) by coating the high-viscosity photocurable resin (5) only on the lower surface of the support film (120) by pulling up the high-viscosity photocurable resin (5) filled in the resin storage tank (110) with one recoating roller (130) and then curing the high-viscosity photocurable resin (5) with light (L) irradiated from the light source unit (160), there is no concern that the high-viscosity photocurable resin (5) in the resin storage tank (110) will be irradiated with light. As a result, since the present invention can selectively curate only the high-viscosity photocurable resin (5) coated on the lower surface of the support film (120), it is possible to prevent discoloration of the high-viscosity photocurable resin (5) due to unnecessary curing.

[0057]

[0058] The release roller (140) is mounted on two sides of the upper surface of the support film (120) spaced apart from the recoating roller (130), and serves to release the high viscosity photocurable resin (5) that has been hardened after being coated on the coating area of ​​the support film (120).

[0059] These two different-shaped rollers (140) are mounted, including a first different-shaped roller (142) mounted on one side of the upper surface of the support film (120) and a second different-shaped roller (144) mounted on the other side opposite to the one side of the upper surface of the support film (120). In this way, the different-shaped film (140) is mounted with two different-shaped rollers (142, 144) mounted on one side and the other side so as to be spaced apart from each other, with one recoating roller (130) interposed therebetween.

[0060] When the high viscosity photocurable resin (5) laminated on the molding plate (150) is photocured, the molding plate (150) is lowered by the thickness of the laminated high viscosity photocurable resin (5), and the roller (140) rotates in the opposite direction to the recoating roller (130) to remove the cured high viscosity photocurable resin (5) from the support film (120) to form each molding layer (10).

[0061] Here, the support film (120) may have a right-angled uneven structure when viewed in cross section, with the recoating roller (130) and the release roller (140) portions mounted on the lower and upper surfaces of the support film (120), respectively. In this way, since the recoating roller (130) and the release roller (140) portions have a right-angled uneven structure, the support film (120) can be stably coupled to the recoating roller (130) and the release roller (140) without strong tension being applied to the recoating roller (130).

[0062]

[0063] The forming plate section (150) is mounted on one side spaced apart from the resin storage tank (110), the recoating roller (130) and the release roller (140), and serves to laminate the high viscosity photocurable resin (5) coated on the coating area on the lower surface of the support film (120) when the recoating roller (130) and the release roller (140) are moved in a horizontal reciprocating motion.

[0064] This forming plate part (150) is placed under the support film (120) and serves as a support for laminating the high-viscosity photocurable resin (5) coated on the coating area on the lower surface of the support film (120). Here, the forming plate part (150) is designed to move up and down in the vertical direction without moving in the horizontal direction, and each forming layer (10) formed from the high-viscosity photocurable resin (5) cured by the light source unit (160) is laminated.

[0065] In this way, when the high viscosity photocurable resin (5) coated on the coating area on the lower surface of the support film (120) is cured by light irradiation from the light source unit (160), the molding plate section (150) is lowered vertically by the amount of the laminated thickness of the cured high viscosity photocurable resin (5).

[0066] To this end, the molding plate portion (150) may include a drive unit and a control unit. The drive unit functions to vertically reciprocate the molding plate portion (150) up and down, and the control unit functions to control the operation of the drive unit. The drive unit responds to a control signal from the control unit to provide power to vertically move the molding plate portion (150) up and down. The drive unit may be any one of a hydraulic, pneumatic, and electric actuator, but is not limited thereto.

[0067] In this way, the top-down high-viscosity 3D printing device (100) according to an embodiment of the present invention coats the high-viscosity photocurable resin (5) on the lower surface of the support film (120) by pulling up one recoating roller (130) while immersing one recoating roller (130) in the high-viscosity photocurable resin (5) with a high molecular weight filled in the resin storage tank (110). Thereafter, the top-down high-viscosity 3D printing device (100) according to an embodiment of the present invention forms a plurality of modeling layers (10) by curing with a light source unit (160) and minimizing the force required for releasing through two release rollers (140), thereby significantly improving the mechanical properties of the plurality of modeling layers (10) and minimizing the amount of the high-viscosity photocurable resin (5) used.

[0068] As a result, the top-down high-viscosity 3D printing device (100) according to the embodiment of the present invention can selectively perform photo-curing only on the high-viscosity photo-curable resin (5) coated on the lower surface of the support film (120) without irradiating the high-viscosity photo-curable resin (5) in the resin storage tank (110), thereby preventing discoloration of the high-viscosity photo-curable resin (5) due to unnecessary photo-curing.

[0069] In addition, the top-down high-viscosity 3D printing device (100) according to an embodiment of the present invention can precisely control the layer thickness of a plurality of modeling layers (10) laminated on the modeling plate (150) by photo-curing the high-viscosity photo-curable resin (5) coated on the lower surface of the support film (120) and then lowering the modeling plate (150) in the vertical direction by the amount of the laminated thickness of the high-viscosity photo-curable resin (5) to release the mold.

[0070] Therefore, the top-down high-viscosity 3D printing device (100) according to the embodiment of the present invention is a method in which the cured high-viscosity photocurable resin (5) is lowered vertically by the layer thickness through the lowering of the molding plate part (150) each time a plurality of molding layers (10) are created, so not only is there no need to adjust the level of the resin storage tank (110), but also there is no need for work such as recoating the cured high-viscosity photocurable resin (5), so there is an effect of greatly improving the process yield.

[0071]

[0072] The light source unit (160) is mounted on the upper side, spaced apart from the forming plate portion (150), and serves to irradiate light onto the high-viscosity photocurable resin (5) positioned on the forming plate portion (150) to harden the high-viscosity photocurable resin (5) and form a plurality of forming layers (10).

[0073] This light source unit (160) includes a laser generator (162) and a scanner (164). The laser generator (162) generates a laser beam for curing a high-viscosity photocurable resin (5), and the scanner (164) controls the laser beam generated from the laser generator (162) to be irradiated only to the high-viscosity photocurable resin (5) coated on the coating area on the lower surface of the support film.

[0074] In this way, in the embodiment of the present invention, an SLA (StereoLithography Apparatus) method can be used that utilizes the principle of irradiating a high-viscosity photocurable resin (5) with laser light (L) and hardening the irradiated portion.

[0075] Here, the light source unit (160) is mounted on the upper side, spaced apart from the forming plate portion (150) and the support film (120), and by irradiating light (L) in the downward direction of the support film (120), the high viscosity photocurable resin (5) coated on the coating area on the lower surface of the support film (120) is cured to form each forming layer (10).

[0076]

[0077] Meanwhile, FIGS. 3 and 4 are cross-sectional views for explaining the operating principle of moving the recoating roller and the molding roller of the present invention in one direction, and FIGS. 5 and 6 are cross-sectional views for explaining the operating principle of moving the recoating roller and the molding roller of the present invention in the other direction, and these will be described in more detail with reference to these.

[0078] First, as shown in FIGS. 3 and 4, the recoating roller (130) is mounted so that its lower portion is inserted into the resin storage tank (110) and immersed in the high-viscosity photocurable resin (5) filled in the resin storage tank (110), and its upper portion is mounted so that it comes into contact with the lower surface of the support film (120) and supports the support film (120). One such recoating roller (130) is mounted in the resin storage tank (110).

[0079] In addition, two heterogeneous rollers (140) are mounted, including a first heterogeneous roller (142) mounted on one side of the upper surface of the support film (120) and a second heterogeneous roller (144) mounted on the other side opposite to one side of the upper surface of the support film (120).

[0080] For example, the recoating roller (130) may have a first radius (d1), and the molded roller (140) may have a second radius (d2) that is equal to or smaller than the first radius (d1). In this case, the second radius (d2) is preferably smaller than the first radius (d1). It is more preferable that the first radius (d1), which is the radius of the recoating roller (130), has a length that is at least twice as long as the second radius (d2), which is the radius of the molded roller (140), and it is even more preferable that it has a length that is three to four times as long.

[0081] In this way, if the radius of the recoating roller (130) is designed to be at least twice as long as the radius of the molding roller (140), the area where the recoating roller (130) comes into contact with the high-viscosity photocurable resin (5) is expanded, making it easy to coat the high-viscosity photocurable resin (5) in the resin storage tank (110) by lifting it to the lower surface of the support film (120). In addition, since a recoating roller (130) having a single large radius is applied, there is a structural advantage in that repair and replacement of the recoating roller (130) are easy.

[0082] At this time, when the recoating roller (130) is rotated in the first direction, the differential roller (140) is rotated in the second direction opposite to the first direction, thereby horizontally moving the recoating roller (130) and differential roller (140) in one direction.

[0083] Meanwhile, as shown in FIGS. 5 and 6, when the recoating roller (130) is rotated in the second direction, the differential roller (140) is rotated in the first direction opposite to the second direction, thereby horizontally moving the recoating roller (130) and differential roller (140) in the opposite direction to one side.

[0084] In this way, in the present invention, the rotation directions of the recoating roller (130) and the differential roller (140) are set to be opposite to each other, and the recoating roller (130) and the differential roller (140) can be freely moved to one side or the other side through the rotation of the recoating roller (130).

[0085]

[0086] Fig. 7 is a schematic diagram showing the recoating roller and the special roller of the present invention in more detail, and Fig. 8 is a plan view for explaining the operating principle of the recoating roller of the present invention.

[0087] As illustrated in FIGS. 7 and 8, a top-down high-viscosity 3D printing device (100) according to an embodiment of the present invention further includes a bracket unit (170) and a resin supply tank (180).

[0088] The bracket unit (170) is mounted on both edges of the recoating roller (130) and the special roller (140), and serves to fix the driving shaft of the recoating roller (130) and the driving shaft of the special roller (140) to each other. By being joined by the bracket unit (170), the recoating roller (130) and the special roller (140) rotate in conjunction with each other.

[0089] A resin supply tank (180) is installed to supply high-viscosity photocurable resin (5) into a resin storage tank (110) through a resin supply pipe (182) connected to the resin storage tank (110). This resin supply tank (180) may be installed on one side spaced apart from the recoating roller (130) and the release roller (140).

[0090] Here, the recoating roller (130) supporting the support film (120) is rotated in a first direction, and the release roller (140) is rotated in a second direction opposite to the first direction, thereby horizontally moving the recoating roller (130) and the release roller (140) in one direction.

[0091] In this way, by horizontally moving the recoating roller (130) and the release roller (140) in one direction, the high viscosity photocurable resin (5) in the resin storage tank (110) can be coated only on the coating area (CA) on the lower surface of the support film (120) using the recoating roller (130).

[0092]

[0093] Meanwhile, FIGS. 9 and 10 are schematic diagrams showing a top-down high-viscosity 3D printing device according to a modified example of the present invention.

[0094] As illustrated in FIGS. 9 and 10, a top-down high-viscosity 3D printing device (200) according to a modified example of the present invention includes a resin storage tank (210), a support film (220), a recoating roller (230), a release roller (240), a forming plate section (250), and a light source unit (260).

[0095] The top-down high-viscosity 3D printing device (200) according to a modified example of the present invention has substantially the same configuration as the top-down high-viscosity 3D printing device according to the embodiment of the present invention described with reference to FIGS. 1 and 2, except for the light source unit (260), so redundant descriptions will be omitted and descriptions will be focused on the differences.

[0096] A top-down high-viscosity 3D printing device (200) according to a modified example of the present invention is mounted at an upper portion spaced apart from a forming plate portion (250), and a DLP (Digital Light Processing) method using a projector as a light source unit (260) for irradiating light onto a high-viscosity photocurable resin (5) positioned on the forming plate portion (250) to harden the high-viscosity photocurable resin (5) to form a plurality of forming layers (10) can be used.

[0097] In this case, the top-down high-viscosity 3D printing device (200) according to the modified example of the present invention is irradiated with light in a top-down manner in the same manner as the top-down high-viscosity 3D printing device according to the embodiment of the present invention described with reference to FIGS. 1 and 2.

[0098]

[0099] The high-viscosity 3D printing device of the top-down type according to the embodiment of the present invention forms a plurality of modeling layers by coating a high-viscosity photocurable resin on the lower surface of a support film by immersing one recoating roller in a high-viscosity photocurable resin with a high molecular weight filled in a resin storage tank and pulling it up with one recoating roller, and then curing it with a light source unit and minimizing the force required for releasing through a release roller, thereby significantly improving the mechanical properties of the plurality of modeling layers and minimizing the amount of high-viscosity photocurable resin used.

[0100] As a result, the top-down high-viscosity 3D printing device according to the embodiment of the present invention can selectively perform photocuring only on the high-viscosity photocurable resin coated on the lower surface of the support film without irradiating the high-viscosity photocurable resin in the resin storage tank with light, thereby preventing discoloration of the high-viscosity photocurable resin due to unnecessary photocuring.

[0101] In addition, the top-down high-viscosity 3D printing device according to an embodiment of the present invention is a method of photo-curing a high-viscosity photo-curable resin coated on the lower surface of a support film, and then lowering the forming plate section in the vertical direction by the thickness of the high-viscosity photo-curable resin to release the mold, so that layer thickness control for a plurality of forming layers laminated on the forming plate section becomes possible.

[0102] In this way, the top-down high-viscosity 3D printing device and its 3D printing method according to an embodiment of the present invention are such that the cured high-viscosity photocurable resin is lowered vertically by the layer thickness through the lowering of the molding plate section each time a plurality of molding layers are created, so not only is there no need to adjust the level of the resin storage tank, but work such as recoating the cured high-viscosity photocurable resin is unnecessary, so there is an effect of greatly improving the process yield.

[0103]

[0104] Hereinafter, a top-down high-viscosity 3D printing method according to an embodiment of the present invention will be described with reference to the attached drawings.

[0105] Figures 11 to 14 are process schematic diagrams for explaining a top-down high-viscosity 3D printing method according to an embodiment of the present invention.

[0106] As shown in Fig. 11, one recoating roller (130) positioned on the upper portion of the forming plate portion (150) and two different rollers (140) mounted on both sides spaced apart from the recoating roller (130) are moved horizontally in one direction, and the high viscosity photocurable resin (5) in the resin storage tank (110) is coated on the coating area on the lower surface of the support film (120) using the recoating roller (130).

[0107] Here, the resin storage tank (110) may have a rectangular parallelepiped shape with an empty space inside, but this is merely an example and it will be obvious that the shape can be applied in various ways. The empty space inside the resin storage tank (110) is filled with a high-viscosity photocurable resin (5). The high-viscosity photocurable resin (5) may have a viscosity of 10,000 to 800,000 cps, a more preferable range may be 100,000 to 600,000 cps, and most preferably 200,000 to 500,000 cps.

[0108] The support film (120) is placed on the upper portion, spaced apart from the resin storage tank (110). It is preferable that the support film (120) be made of a transparent polymer material that allows light irradiated from the light source unit (160) to easily pass through and has excellent strength and rigidity. To this end, the support film (120) may include any one selected from among an FEP film (fluorinated ethylene propylene), a PFA film (perfluoroalkoxy film), a PTFE film (polytetrafluoroethylene film), and an ACF film (anisotropic conductive film), and among these, it is more preferable to use an FEP film.

[0109] It is preferable to use a support film (120) having a thickness of 200 μm or less, because a thickness of 200 μm or less ensures high transmittance while also ensuring sufficient durability.

[0110] The recoating roller (130) is mounted so that its lower part is inserted into the resin storage tank (110) and is immersed in the high viscosity photocurable resin (5) filled in the resin storage tank (110), and its upper part is mounted so that it comes into contact with the lower surface of the support film (120) and supports the support film (120).

[0111] One such recoating roller (130) is mounted in the resin storage tank (110). In this way, the present invention coats the lower surface of the support film (120) with the high-viscosity photocurable resin (5) by immersing one recoating roller (130) in the high-viscosity photocurable resin (5) with a high molecular weight filled in the resin storage tank (110) and pulling it up with one recoating roller (130). Therefore, it becomes possible to minimize the amount of the high-viscosity photocurable resin (5) used.

[0112] In this step, the recoating roller (130) supporting the support film (120) is rotated in a first direction, and the release roller (140) is rotated in a second direction opposite to the first direction. In this way, the recoating roller (130) is rotated in the first direction, and the release roller (140) is rotated in the second direction opposite to the first direction, thereby horizontally moving the recoating roller (130) and the release roller (140) in one direction.

[0113]

[0114] Next, as illustrated in Fig. 12, using a light source unit (160) mounted on the upper side spaced apart from the forming plate portion (150), light is irradiated onto the high-viscosity photocurable resin (5) positioned on the forming plate portion (150) to harden the high-viscosity photocurable resin (5).

[0115] In this step, the light source unit (160) includes a laser generator (162) and a scanner (164). The laser generator (162) generates a laser beam for curing a high-viscosity photocurable resin (5), and the scanner (164) controls the laser beam generated from the laser generator (162) to be irradiated only to the high-viscosity photocurable resin (5) coated on the coating area on the lower surface of the support film.

[0116] In this way, the light source unit (160) is mounted on the upper side, spaced apart from the forming plate portion (150) and the support film (120), and by irradiating light in the downward direction of the support film (120), the high viscosity photocurable resin (5) coated on the coating area on the lower surface of the support film (120) is cured.

[0117]

[0118] As shown in Fig. 13, the molding plate part (150) is lowered vertically by the thickness of the laminate of the cured high-viscosity photocurable resin (5), and the cured high-viscosity photocurable resin (5) is released using a release roller (140) to form a molding layer (10).

[0119] In this step, the molding roller (140) lowers the molding plate (150) by the thickness of the high viscosity photocurable resin (5) laminated on the molding plate (150) after the high viscosity photocurable resin (5) is photocured, thereby rotating in the opposite direction to the recoating roller (130) to separate the cured high viscosity photocurable resin (5) from the support film (120) to form each molding layer (10).

[0120]

[0121] As shown in Fig. 14, one recoating roller (130) positioned on the upper portion of the forming plate portion (150) and two different rollers (140) mounted on both sides spaced apart from the recoating roller (130) are horizontally moved in the opposite direction to one side, and the high viscosity photocurable resin (5) in the resin storage tank (110) is coated on the coating area on the lower surface of the support film (120) using the recoating roller (130).

[0122] In this step, the recoating roller (130) supporting the support film (120) is rotated in a second direction, and the release roller (140) is rotated in a first direction opposite to the second direction. In this way, the recoating roller (130) is rotated in the second direction, and the release roller (140) is rotated in the first direction opposite to the second direction, thereby horizontally moving the recoating roller (130) and the release roller (140) in opposite directions.

[0123] Next, using a light source unit (160) mounted on the upper side and spaced apart from the molding plate section (150), light is irradiated onto the high-viscosity photocurable resin (5) positioned on the molding plate section (150) to harden the high-viscosity photocurable resin (5).

[0124] Next, the molding plate part (150) is lowered vertically by the thickness of the laminate of the hardened high-viscosity photocurable resin (5), and the hardened high-viscosity photocurable resin (5) is released using a release roller (140) to form a molding layer (10).

[0125] It is preferable to repeat the above-described series of steps at least twice. By performing this series of steps, a plurality of modeling layers (10) can be formed on the modeling plate (150) in which modeling layers are sequentially laminated.

[0126]

[0127] While the above description focuses on specific embodiments of the present invention, those skilled in the art will appreciate that various modifications and variations can be made. Such modifications and variations, as long as they do not depart from the scope of the technical concept provided by the present invention, are considered to be within the scope of the present invention. Therefore, the scope of the present invention should be determined by the claims set forth below.

[0128]

[0129] [Explanation of symbols]

[0130] 100: 3D printing device 110: Resin storage tank

[0131] 120: Support film 130: Recoating roller

[0132] 140: Deformed roller 142: First deformed roller

[0133] 144: Second heterogeneous roller 150: Forming plate section

[0134] 160: Light source unit 162: Laser generator

[0135] 164: Scanner 170: Bracket Unit

[0136] 180: Resin storage tank 5: High viscosity photocurable resin

[0137] 10: Multiple shaping layers d1: First radius

[0138] d2: second radius

Claims

1. Resin storage tank filled with high viscosity photocurable resin; A support film placed on the upper side, spaced apart from the above resin storage tank; A recoating roller is disposed between the resin storage tank and the support film to support the lower surface of the support film and coat the high viscosity photocurable resin in the resin storage tank on the coating area of ​​the support film; A release roller, two of which are mounted on both sides spaced apart from the recoating roller on the upper surface of the support film, for releasing the high viscosity photocurable resin that has been coated on the coating area of ​​the support film and then cured; A molding plate mounted on one side spaced apart from the resin storage tank, the recoating roller and the release roller, for laminating a high viscosity photocurable resin coated on the coating area on the lower surface of the support film when the recoating roller and the release roller are moved in a horizontal reciprocating motion; and A light source unit mounted on an upper portion spaced apart from the above-mentioned forming plate portion, for irradiating light onto the high-viscosity photocurable resin positioned on the above-mentioned forming plate portion to harden the high-viscosity photocurable resin and form a plurality of forming layers; characterized by including, Top-down high-viscosity 3D printing device.

2. In paragraph 1, The above high viscosity photocurable resin Characterized by having a viscosity of 10,000 to 800,000 cps, Top-down high-viscosity 3D printing device.

3. In paragraph 1, The above recoating roller The lower part is mounted so as to be inserted into the resin storage tank and is mounted so as to be immersed in the high viscosity photocurable resin filled in the resin storage tank, The upper part is mounted so as to be in contact with the lower surface of the support film, and is characterized in that it supports the support film. Top-down high-viscosity 3D printing device.

4. In paragraph 3, The above recoating roller is mounted in one piece within the resin storage tank, The above-mentioned heterogeneous roller is characterized in that two are mounted, including a first heterogeneous roller mounted on one side of the upper surface of the support film and a second heterogeneous roller mounted on the other side opposite to the one side of the upper surface of the support film. Top-down high-viscosity 3D printing device.

5. In paragraph 1, When the recoating roller is rotated in the first direction, the release roller is rotated in a second direction opposite to the first direction to horizontally move the recoating roller and the release roller in one direction. When the recoating roller is rotated in the second direction, the release roller is rotated in the first direction opposite to the second direction, thereby horizontally moving the recoating roller and the release roller in the opposite direction to one side. Top-down high-viscosity 3D printing device.

6. In paragraph 1, The above 3D printing device A bracket unit mounted on both edges of the recoating roller and the molding roller to mutually fix the driving shaft of the recoating roller and the driving shaft of the molding roller; and A resin storage tank for supplying high-viscosity photocurable resin into the resin storage tank through a resin supply pipe connected to the above resin storage tank; characterized by further including, Top-down high-viscosity 3D printing device.

7. In paragraph 1, The above-mentioned shaping plate part When the high viscosity photocurable resin coated on the coating area on the lower surface of the support film is cured by light irradiation from the light source unit, it is characterized in that it is lowered in the vertical direction by the thickness of the laminate of the cured high viscosity photocurable resin. Top-down high-viscosity 3D printing device. 8.(a) A step of coating a high-viscosity photocurable resin in a resin storage tank on a coating area on the lower surface of a support film using a recoating roller while horizontally moving one recoating roller located on the upper portion of a molding plate section and two different rollers mounted on both sides spaced apart from the recoating roller in one direction; (b) a step of irradiating light onto a high-viscosity photocurable resin positioned on the forming plate portion using a light source unit mounted on the upper portion spaced apart from the forming plate portion to harden the high-viscosity photocurable resin; and (c) a step of forming a molding layer by releasing the cured high-viscosity photocurable resin using the release roller while lowering the molding plate section in the vertical direction by the thickness of the laminate of the cured high-viscosity photocurable resin; characterized by including, Top-down high-viscosity 3D printing method.

9. In paragraph 8, In step (a) above, The above high viscosity photocurable resin Characterized by having a viscosity of 10,000 to 800,000 cps, Top-down high-viscosity 3D printing method.

10. In paragraph 8, In step (a) above, The above recoating roller is mounted in one piece within the resin storage tank, The above-mentioned heterogeneous roller is characterized in that two are mounted, including a first heterogeneous roller mounted on one side of the upper surface of the support film and a second heterogeneous roller mounted on the other side opposite to the one side of the upper surface of the support film. Top-down high-viscosity 3D printing method.

11. In paragraph 8, After step (c) above, (d) a step of coating a high-viscosity photocurable resin in a resin storage tank on a coating area on the lower surface of a support film using the recoating roller while horizontally moving one recoating roller located on the upper portion of the molding plate portion and two of the release rollers mounted on both sides spaced apart from the recoating roller in one direction opposite to the other direction; (e) a step of irradiating light onto a high-viscosity photocurable resin positioned on the molding plate portion using a light source unit mounted on the upper portion spaced apart from the molding plate portion to harden the high-viscosity photocurable resin; and (f) a step of forming a molding layer by releasing the cured high-viscosity photocurable resin using the release roller while lowering the molding plate section in the vertical direction by the thickness of the laminate of the cured high-viscosity photocurable resin; A top-down high-viscosity 3D printing method characterized by further including:

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