CN1769032A - Quick forming method by adoption of projection technique - Google Patents

Quick forming method by adoption of projection technique Download PDF

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Publication number
CN1769032A
CN1769032A CN 200410009731 CN200410009731A CN1769032A CN 1769032 A CN1769032 A CN 1769032A CN 200410009731 CN200410009731 CN 200410009731 CN 200410009731 A CN200410009731 A CN 200410009731A CN 1769032 A CN1769032 A CN 1769032A
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photosensitive resin
projector
lamp
computer
section
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CN100391721C (en
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谭昊涯
曹瑞军
谭东风
童家仙
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Abstract

The invention belongs to the producing area, which uses modern shadow casting technique and computer image processing technique to process the illumination solidification modeling on the surface of liquid photosensitive resin to form the three-dimensional solid quickly. The invention processes the sectional mould data of three-dimensional solid via the computer fast shaping processing technique to generate the digital grid image data which can be directly used in projection, to be transformed into digital optical signal via the digital image projector, and adjusted by different time and space patterns to be irradiated over the surface of photosensitive resin to solidify it.

Description

Adopt the method for the rapid shaping of shadow casting technique
Technical field
The invention belongs to the manufacturing field, particularly adopt modern shadow casting technique and computer graphics disposal technology, on the liquid photosensitive resin surface, carry out the illumination curing moulding, form the method for 3D solid fast.
Background technology
Rapid shaping (Rapid Prototyping is called for short RP) is rapid, the intelligentized novel forming method that has produced since Computer Control Technology is born, and has started a revolution of manufacturing.Around adopting Computer Control Technology to produce a series of quick molding methods.As the disclosed technical scheme of US4575330, SLS (the Selective Laser Sintering) method of U.S. DTM company development, FDM (the Fused Deposition Mfg) method of the Scott Crump engineer invention of the U.S., LOM (the Laminated Object Mfg) method of companies such as U.S. Gropp exploitation, the SL of MIT (Stereolithography) method, SGC (the Solid Ground Curing) method that the CUBITAL company of Israel proposes, the 3D Printing method of invention such as the Emanuel Sachs of the Massachusetts Institute of Technology, the length-varying linear scanning SLS method that North China engineering college proposes and high-power laser diode linear array energy source SLS method or the like.A common feature of foregoing invention or technology is that two dimension is shaped under computer control, forms 3D solid by stack.Remove method (Material Decrease) with respect to the so-called material of excess stock on the part blank being got rid of by traditional machining (car, cut, mill, brill, mill etc.) means and further improvement has been arranged, above-mentioned these methods general designation material incremental methods (Material Increase).At present, the key issue of the whole bag of tricks all concentrates on aspects such as manufacturing cost, manufacturing speed and the accuracy of manufacture.
In many RP methods, what development was very fast, application is wider is liquid photosensitive resin selectivity curing molding method.Xiang Guan method mainly is SL method and SGC method therewith.The SL method claims stereolithography again, and this method is used ultraviolet light beam or UV laser beam scanning liquid photosensitive resin and curing molding.This method is formed face by the line of scanning one rule, is superimposed as 3D solid again, thereby consuming time longer, and shaping speed is slower.If use laser beam flying, because laser tube costliness and life-span are limited, the disposable input and the operating cost of the method are all higher; Ultraviolet light beam scanning, though can reduce cost, hot spot is bigger, and photosensitive resin curing molding precision is greatly reduced.The SGC method is also referred to as mask (Mask) solidification method, it uses the light leak plate of similar projection film, the shadow and the irradiation that produce part by the light leak plate make the liquid photosensitive resin curing molding on the liquid photosensitive resin surface, though more than ground of this method energy are cured resin faces and stack formation 3D solid directly, has improved shaping speed.But resin shrinks when solidifying and concentrates in flakes, cause formed precision relatively poor, more distinct issues are to use this method to need to be in advance light leak plate of each layer making of forming part, thereby program is numerous and diverse, use cost is higher, add that automaticity is lower, so this method is used more widely never.
Summary of the invention
The objective of the invention is to solidify the problem that the liquid photosensitive resin moulding exists at SL method and SGC method, comprehensive modern shadow casting technique, the computer graphics disposal technology etc. of adopting, ultraviolet light beam or UV laser beam scanning means are replaced with projector, a kind of quick molding method that adopts shadow casting technique is provided.
The step of shadow casting technique's quick molding method that adopts of the present invention comprises:
" section " model data from 3D solid, machine raster graphic treatment technology generates the digital raster graph data that can be used for direct projection as calculated, transform, generate digital optical signal through digital picture projector, and after different time and space form adjustment, shine the photosensitive resin liquid level and make irradiated resin solidification moulding.This is the process that information, energy and a structure of matter and form transform and change, and generates radiation data, moulding radiation source system imaging and resin irradiation and solidifies flow process along computer.
(1). data are obtained
Obtain digital three-dimensional physical model (as the three-dimensional entity model that the adopts the STL form to represent) data of object by instruments such as computer aided design software or entity measuring equipment, and these data are input in the computer of make-up machine, three-dimensional entity model data to input are handled, with threedimensional model along any one party in the three-dimensional coordinate direction of principal axis to (the normally Z-direction in the 3-D walls and floor) hierarchy slicing (promptly adopting the crossing intersection figure that obtains of corresponding X-Y plane and three-dimensional entity model), obtain one group of two dimension slicing information, wherein the shape of each section is a figure by some closed areas (general represent with end to end one group of straightway in the direction of the clock, then use by end to end one group of straightway counterclockwise for " hole " zone that wherein may exist and represent) composition.
(2). moulding
(2.1) layer is prepared: the liquid resin liquid level at the resin liquid bath before the illumination is ready to skim (generally being 0.1~1 millimeter) photosensitive resin to be solidified.
Before just having begun moulding, this one deck photosensitive resin is exactly one deck photosensitive resin on the product pallet; After treating that one deck photosensitive resin solidifies, lift is by driving tray one deck distance that suitably descends, to be ready to skim resin to be solidified again on the cured layer just, the scraper of a horizontal reciprocating movement is used for eliminating the resin bed problem of non-uniform owing to photosensitive resin viscosity and surface tension generation, and guarantees the stability of thin layer photosensitive resin liquid level position and the planarization of liquid level.
(2.2) layer irradiation with solidify: this is the critical process of the object moulding that relates to of this method, comprises 3 contents.
(2.2.1) form " section " cross section illumination pattern:
At first, utilize computer raster graphic treatment technology from one group of two dimension slicing graphical information that step (1) obtains, show the subclass figure of cutting into slices one by one in proper order along model fabrication orientation (as Z-direction), and this graph data is directly outputed to the projector that is connected with computer by connecting channel;
(2.2.2) face of " section " figure irradiation:
The section subclass graph data that projector will be one by one obtains from step (2.2.1) change the optical signalling of figure into, to the photosensitive resin liquid level, and make photosensitive resin curing with the direct prolonged exposure of static graphics.Connecting channel between computer and the projector is connecting line normally, the mechanically beam flying of whole process.
(2.2.3) mode of minimizing resin solidification error:
In same photosensitive resin layer forming process, for (face) that reduces photosensitive resin layer solidifies error, repeatedly repeating step (2.2.1) and step (2.2.2).
(2.3) solidify, pile up moulding layer by layer:
Behind photosensitive resin one deck curing molding, make-up machine repeats the step in step (2.1), the step (2.2), forms until whole product.
(3). post processing
After the product moulding,, comprise that the taking-up, cleaning, removal of product supported to the aid in treatment technology that product carries out, polishing, surface spraying etc.
Described projector is the combination of a projector or an above projector.
The projection of described projector comprises LCD pattern, DMD pattern.
The light source of described projector comprises high-pressure sodium lamp, arc lamp, iodine-tungsten lamp, fluorescent lamp, incandescent lamp, Metal halogen lamp, UHP lamp, UHE lamp or xenon lamp.
The power of described lamp is 50W~10KW, and wave-length coverage is 40nm~800nm.
Described each irradiation plane is made up of several difformities, separate little plane, or is made up of infinite point.
The moulding of described each individual layer (product moulding top layer is with respect to the invariant position of photosensitive resin liquid level) is by more than 2 times or 2 times, and each light application time was as the criterion so that the individual layer photosensitive resin solidifies fully between 0.01 second to 100 seconds.
The present invention has made full use of the equipment of existing quick molding method, but will be wherein ultraviolet light beam or UV laser beam produce with scanning means and replace with projector, its rapidform machine is made up of 3 parts:
1, projector system
Employing is based on transmission-type, reflection type liquid crystal technique, or the projector of the DLP technology of digital micro-mirror device (DMD) etc.
One-of-a-kind system that the one-of-a-kind system of fixed-site or band stepper motor driving device can move horizontally or the multi-computer system that makes up by a plurality of projectors.
2, computer system
Have and handle and the computer system that shows digital three-dimensional model and two-value raster graphic ability.
3, other parts
The photosensitive resin of forming process indispensability and liquid bath thereof, scraper, lift and pallet, photosensitive resin autocompensation installation, power-supply system and make attaching parts of above-mentioned part co-ordination etc.
The workflow of the inventive method as shown in Figure 1.At first obtain the three-dimensional modeling data of wanting shaped object by computer system, the data that this threedimensional model are divided into one group of section figure, shine the top layer photosensitive resin is solidified by the projector system figure of will cutting into slices, Machinery Control System to become the type photosensitive resin surface handle and form new one deck the photosensitive resin liquid level so that the usefulness of next moulding solidify layer by layer until forming whole article.The structure of rapidform machine of the present invention as shown in Figure 2, rapidform machine mainly is made up of computer system, projector system, Machinery Control System.A kind of irradiation pattern of the present invention as shown in Figure 3.The computer control software flow process that is used for the inventive method as shown in Figure 4, computer generates the flow process of irradiation pattern and controlled entity moulding.
The present invention has following characteristics:
1. computer generates radiation data
(1) utilize ripe computer raster graphic technology to generate the static dot pattern of two-value of " section ", and simply corresponding relation (as one to one) is directly used in the optical imagery (being array of light spots in fact) that driving projector is converted into the photosensitive resin liquid face of irradiation with it, need not generate to cover " section " is the traverse scanning sequence of purpose, need not generate the control light beam carries out linear scan to the photosensitive resin liquid level command sequence.
(2) adopt by several coverings " section " but the figure that disjunct mutually " point " (approximate mathematical sealing connected region) formed shines photosensitive resin liquid face, make each " point " while curing independently.By (least twice is not repeatedly limit) above-mentioned irradiation repeatedly whole " section " solidified.
2. moulding radiation source
(1) adopt various based on transmission-type, reflection type liquid crystal (LCD) technology and adopt the projection imaging device of digital micro-mirror device (DMD) (but being not limited thereto) such as DLP technology.Various spot lights, as (being not limited thereto) such as high-pressure sodium lamp, arc lamp, fluorescent lamp, Metal halogen lamp, UHP lamp, UHE lamp or xenon lamps as the moulding light source.
(2) adopt shadow casting technique with radiation mode irradiation, curing photosensitive resin, need not carry out beam flying and need not corollary equipment,
(3) by adjusting the camera lens amplification or dwindling irradiation image, size and the precision that can easily control and regulate moulding.
(4) cooperate with computer control by projection arrangement arranged side by side, realize the combination and the splicing of a plurality of projectors easily, can be adjusted to molded dimension and precision easily.
3. shine and curing
(1) with face irradiation rather than point or line irradiation, improved shaping speed significantly.
(2) with static graphics prolonged exposure rather than the instantaneous irradiation of motion graphics, can control the light exposure easily, very big range of choice be arranged for type, the energy of light source.
Method of the present invention can be applicable to various fields such as architectural design, machine die design, Design of Plastic Mould, sample displaying.
Quick molding method of the present invention has many outstanding characteristics, has overcome the drawback that other quick molding method is difficult to go beyond, and can make rapid shaping technique reach a new level.Specifically describe characteristics of the present invention and effect below by example, but do not represent the whole of this quick molding method.
Description of drawings
Fig. 1. the workflow schematic diagram of the inventive method.
Fig. 2. the structural representation of the used rapidform machine of the present invention.
Fig. 3. illumination pattern schematic diagram of the present invention.
Fig. 4. be used for the computer control software flow chart of the inventive method.
Reference numeral
1. projector's 2. object digital three-dimensional models 3. computers 4. lifts
5. scraper 6. liquid baths 7. products 8. pallets
9. projecting figure 10. liquid level 11. " section " borders 12. " point "
13. the part that hole 14. is not covered by " point "
The specific embodiment
Embodiment 1:
The structure of rapidform machine as shown in Figure 2, the 50kg DuPont SOMOS 6100 photo-curing resins of in liquid bath 6, packing into, the TGC-1 that packs in computer 3 controls software (TGC-1 control software flow as shown in Figure 4), can show the digital three-dimensional model 2 of object by computer display; The projector 1 that is connected with computer is positioned at the top of pallet 8, photosensitive resin on the pallet is provided by liquid bath 6, be the constant distance of the photosensitive resin liquid level 10 on the maintenance pallet 6 with projector, make the feature size of projecting figure 9 on the photosensitive resin liquid level keep the same, the lifting of pallet 8 is adjusted by lift 4; The scraper 5 of a horizontal reciprocating movement is installed on the liquid bath 6, guarantees the stability of thin layer photosensitive resin liquid level position and the planarization of liquid level.
Illumination pattern as shown in Figure 3, it is 11 that object covers " section " border, by several coverings " section " but disjunct mutually " point " 12 figures of forming shine photosensitive resin liquid face, makes respectively " point " while curing independently.By above-mentioned irradiation repeatedly whole " section " solidified; The part that is covered by " point " is not 14, and the hole of object is 13.
The workflow of the inventive method as shown in Figure 1.
(1) TGC-1 control software is handled the product three-dimensional modeling data of input, with threedimensional model along the Z-direction hierarchy slicing in the three-dimensional coordinate direction of principal axis, thereby obtain one group of two dimension slicing information, wherein the shape of each section is a figure of being made up of several regions (wherein having " hole ").
(2) one group of two dimension slicing information that step (1) is obtained is utilized TGC-1 control software to show each section one by one along model layering Z-direction, and data are directly outputed to the projector that is connected with computer by holding wire; " section " raster graphics that projector will obtain changes the optical signalling of figure into, with the liquid level of the direct prolonged exposure of static graphics to photosensitive resin, and photosensitive resin is solidified.
(3) behind photosensitive resin one deck curing molding, make-up machine repeats step (2), and until one group two dimension slicing information processing, the end of transmission of TGC-1 control software with the model that obtains, whole product forms.
After the product moulding is finished, product is taken out from liquid bath, cleans.
Projector's parameter: three DMD reflection modes, resolution ratio is 1024 * 768, the high-pressure sodium lamp of light source power 10KW, wavelength 40nm~800nm.
Control parameter: irradiated area: 200mm * 200mm
Shaped object shape: cube
Shaped object size: 100mm * 100mm * 100mm
Every layer thickness of shaped object forming process: 0.1mm
The total umber of exposures of moulding entity: 3000 times
Each exposure time: 0.5 second
Result of the test: molding time: 40 minutes (containing strickling action and switching irradiation pattern required time that layer is prepared)
Entity size: 99.46m * 99.46m * 99.83mm
Formed precision: X-axis: 0.19%
Y-axis: 0.19%
Z axle: 0.11%.
Embodiment 2:
The structure of rapidform machine and quick molding method such as embodiment 1.
Projector's parameter: three LCD transmission modes, resolution ratio are 800 * 600, light source 500W, iodine-tungsten lamp, wavelength 40nm~800nm.
Control parameter: irradiated area: 150mm * 150mm
Forming shape: cube
Compact dimensions: 100mm * 100mm * 100mm
Support size: 100mm * 100mm * 10mm
Every layer thickness of shaped object forming process: 0.1mm
Umber of exposures: support 50 times
The total umber of exposures of moulding entity: 10000 times
Each exposure time: 1.0 seconds
Result of the test: molding time: 270 minutes (containing strickling action and switching irradiation pattern required time that layer is prepared)
Entity size: 99.66mm * 9.66mm * 99.85mm
Formed precision: X-axis: 0.34%
Y-axis: 0.34%
Z axle: 0.15%
Annotate: support is for ease of product being separated easily with pallet or making product overhang the supplementary structure of the stent-type that does not partly drop and design in threedimensional model.
Embodiment 3:
The structure of rapidform machine and quick molding method such as embodiment 1.
Projector's parameter: three LCD reflection modes, resolution ratio is 1024 * 768, light source 50W, UHP lamp, wavelength 40nm~800nm.
Control parameter: irradiated area: 120mm * 120mm
Forming shape: cube
Compact dimensions: 100mm * 100mm * 100mm
Support size: 100mm * 100mm * 10mm
Every layer thickness of shaped object forming process: 0.1mm
Umber of exposures: support 50 times
The total umber of exposures of moulding entity: 10000 times
Each exposure time: 1.0 seconds
Result of the test: molding time: 386 minutes (containing strickling action and switching irradiation pattern required time that layer is prepared)
Entity size: 99.66mm * 9.66mm * 99.85mm
Formed precision: X-axis: 0.21%
Y-axis: 0.21%
Z axle: 0.13%.

Claims (10)

1. method that adopts the rapid shaping of shadow casting technique, comprise that data are obtained, moulding, product moulding post processing, it is characterized in that: the graphics digital signal of the two dimension slicing information of one group of object model that the projector of make-up machine will obtain, be converted to the optical signalling of the liquid level that shines photosensitive resin, with the direct prolonged exposure of static graphics, and photosensitive resin is solidified.
2. method according to claim 1, it is characterized in that: the graphics digital signal of the two dimension slicing information of one group of object model that described projector obtains, the computer that is make-up machine is handled the entity three-dimensional modeling data of input, with threedimensional model along any one party in the three-dimensional coordinate direction of principal axis to hierarchy slicing, thereby obtain one group of two dimension slicing information, wherein the shape of each section is a figure of being made up of several regions.
3. method according to claim 1 is characterized in that, described layer irradiation with curing schedule is:
(1) forms the serial section illumination pattern
With one group of two dimension slicing information that the computer of make-up machine obtains, utilize computer raster graphic treatment technology to show each section one by one, and data are directly outputed to the projector that is connected with computer by holding wire along the model fabrication orientation;
(2) the face irradiation of section figure
The section raster graphics that projector will obtain from step (1) one by one changes the optical signalling of figure into, with the liquid level of the direct prolonged exposure of static graphics to photosensitive resin, and photosensitive resin is solidified;
(3) solidify, pile up moulding layer by layer
Behind photosensitive resin one deck curing molding, make-up machine repeats step (1), step (2), and until one group two dimension slicing information processing, the end of transmission of computer with the model that obtains, whole product forms.
4. method according to claim 3 is characterized in that, in the described same photosensitive resin layer forming process, step (1) shows the subclass figure of each section, and data are directly outputed to the projector that is connected with computer by holding wire; And step (2) projector section subclass graph data that step (1) is obtained changes the optical signalling of static graphics into, shines directly into the liquid level of photosensitive resin, and the photosensitive resin step of curing is repeated more than 1 time.
5. according to claim 1,2,3 or 4 described methods, it is characterized in that: the projection of described projector comprises LCD pattern, DMD pattern.
6. according to claim 1,2,3 or 4 described methods, it is characterized in that: described projector is the combination of a projector or an above projector.
7. according to claim 1,2,3 or 4 described methods, it is characterized in that: the light source of described projector comprises high-pressure sodium lamp, arc lamp, iodine-tungsten lamp, fluorescent lamp, incandescent lamp, Metal halogen lamp, UHP lamp, UHE lamp or xenon lamp.
8. method according to claim 7 is characterized in that: the power of described lamp is 50W~10KW, and wave-length coverage is 40nm~800nm.
9. method according to claim 1 is characterized in that: the subclass figure of section is made of on the irradiation plane of described each layer several difformities, separate little plane.
10. according to claim 1,3 or 4 described methods, it is characterized in that: described each light application time is between 0.01 second to 100 seconds.
CNB2004100097319A 2004-10-29 2004-10-29 Quick forming method by adoption of projection technique Expired - Fee Related CN100391721C (en)

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CN105904727A (en) * 2016-04-19 2016-08-31 周宏志 DLP-based photocuring 3D printing forming method, system and device
CN106113498A (en) * 2016-06-23 2016-11-16 唐天 A kind of forming method
CN106042390A (en) * 2016-07-28 2016-10-26 北京工业大学 Multi-source large-scale face exposure 3D printing method
CN106974738A (en) * 2017-03-17 2017-07-25 西安增材制造国家研究院有限公司 A kind of method of the 3D printing dental impression tray based on DLP techniques
CN108274745A (en) * 2017-12-29 2018-07-13 深圳摩方新材科技有限公司 A kind of stepping splicing 3D printing system and Method of printing
CN108274745B (en) * 2017-12-29 2021-02-12 深圳摩方新材科技有限公司 Stepping splicing 3D printing system and printing method
CN109501245A (en) * 2018-10-19 2019-03-22 上海光琢科技有限公司 Photocuring 3D printing method based on pulsed exposure
CN109719954A (en) * 2019-01-15 2019-05-07 北京科技大学 A kind of DLP photocuring increasing material manufacturing surface quality improvement method

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