发明内容 SUMMARY

本发明的目的在于提供一种光固化与熔融沉积集成的复合快速成形方法和装置，能够有效集成典型的熔融沉积成形方法FDM和典型的光固化成形方法SL，通过二者的优势互补，实现高性能原型件的复合成形。 Object of the present invention is to provide a photocurable composite integrated with fused deposition rapid prototyping methods and apparatus can be effectively integrated typical FDM Fused Deposition Modeling Method and typical photocurable molding method SL, by two complementary, high forming a composite performance of prototype parts.

本发明要解决的技术问题是：目前的快速成形技术具有技术初期的典型特点，即每一种成形方法均有其对应的成形设备，硬件结构自成体系、相对封闭，而且FDM和SL的实现机构有很大的差异性，原有的机构体系无法实现不同成形方法的互补集成，所以要实现不同快速成形方法FDM和SL的复合成形，必须解决以下技术问题：(1)可兼容FDM和SL两种快速成形方法的硬件体系结构；(2)FDM和SL两种方法集成的复合成形工艺及其控制方法。 Technical problem to be solved by the present invention are: The current typical of rapid prototyping technology with early technology, i.e. each molding method has its corresponding forming apparatus, self-contained hardware structure, a relatively closed, and the realization of FDM and SL institutions have great differences, the original institutional system can not achieve the integration of different complementary shaping method, so to achieve different FDM rapid prototyping methods and SL composite molding technology must address the following questions: (1) compatible with FDM and SL (2) FDM and composite technology and control method to integrate the two methods of forming SL; hardware architecture of two rapid prototyping methods.

为了达到上述目的，本发明的构思是：本发明提出不同快速成形工艺过程集成的复合成形思想，它不同于FDM和SL等快速成形单体技术，也不同于以往的快速成形集成方法，采用FDM和SL两种工艺共同制作三维实体，着眼于制作工艺过程的集成，由于各快速成形方法都基于相同的分层/累加成形原理，故集成成本低，易于实现。 To achieve the above purpose, the inventive concept is: The present invention proposes a different rapid prototyping processes integrated composite forming ideas, which is different from FDM rapid prototyping and other monomers and SL technology, but also different from the previous integrated rapid prototyping method using FDM and SL co-produced three-dimensional solid two processes, focusing on the integration of the production process, due to the various rapid prototyping methods are based on the same hierarchical / accumulate forming principle, it is a low cost integrated, easy to implement.

(1)复合成形新结构通过对FDM和SL各成形方法的功能需求分析，评估各成形机构功能模块的通用度，提出了复合成形的新体系结构，主要由三维运动系统和成形自动切换系统组成。 (1) compound forming a new structure of FDM and SL by each method of forming functional requirements analysis to assess the degree of each of the forming mechanism common functional modules, a new architecture of complex shaped mainly by forming a three-dimensional motion systems and automatic switching system components .

SL与FDM均需三维运动系统，但采用不同的机构实现：SL通过振镜转动实现XY平面光路扫描，基础平台实现Z向升降运动，如图1所示；FDM将喷头安装在XY平面运动机构上，喷头可实现XY平面扫描运动和Z向升降运动，基础平台也可做Z向升降运动，如图2所示。 SL and FDM systems required three-dimensional motion, but with a different mechanism to achieve: SL realized by rotating galvanometer scanning light path XY plane, Z-direction based platform lifting movement, shown in Figure 1; FDM nozzle mounted on the XY plane motion mechanism , the nozzle can be achieved XY plane scanning movement and Z movement to lift the foundation platform to do Z lifting movement, as shown in Figure 2. 二者原有机构很难直接集成。 Both difficult to directly integrate existing institutions.

如果将SL基于光学器件的刚性光路系统改造为基于光纤的柔性光路系统，则二者的运动系统可统一成XY平面移动机构和Z向升降平台组成的三维运动系统，唯一区别是移动机构上夹持的成形头不同，这样可方便、低成本地实现二者集成。 If the SL-based system reform rigid optical path of the optical device is a flexible optical system fiber-based, the two motion systems can be unified into a three-dimensional motion system XY plane moving mechanism and Z to the lifting platform composed only difference is that the moving mechanism folder hold different shaped head, so that can be easily and cost-effectively achieve both of integration.

本发明由XY平面运动机构和Z向升降基础平台组成统一的三维运动系统，并将SL基于光学器件的刚性光路成形系统改造为SL柔性成形头系统，该柔性成形头系统包含成形光源、光纤组成的柔性光路系统和光聚焦头，从而使上述三维运动系统可兼容FDM与SL，如图3所示。 The invention consists of the XY plane and Z movement mechanism to lift the base platform consisting of a unified system of three-dimensional motion and optical path SL rigid molded optics-based system transformation for SL flexible forming head system, the flexible system comprises forming the forming head light, optical fibers flexible optical system and the optical focusing head, so that said three-dimensional motion FDM system is compatible with SL, as shown in Figure 3.

为了实现FDM与SL的复合成形，上面的SL柔性成形头和FDM喷头必须可自由切换，因此本发明在XY平面运动机构上安装一个启闭式夹持机构形成成形头自动切换系统，如图4所示。 To achieve FDM forming composite SL, SL flexible forming above the head and FDM nozzle must be free to switch, the present invention is mounted on the XY plane motion mechanism to form an opening and closing ceremony clamping mechanism forming head automatic switching system, as shown in Figure 4 Fig. 该夹持机构可以夹持或放下FDM喷头，也可夹持或放下SL成形头，从而实现不同成形头的自由切换；该夹持机构可以在XY平面上实现任意轨迹运动，实现FDM和SL工艺要求的扫描运动。 The clamping mechanism may clamp down FDM or nozzle, can be clamped or SL forming head down, in order to achieve the freedom to switch different forming heads; the holding mechanism may be arbitrary trajectory on the XY plane, and SL processes achieve FDM scanning motion required.

(2)复合成形工艺及控制方法和SL及FDM工艺一样，复合成形工艺首先需要建立目标实体原型件的三维CAD模型，并对该模型在Z轴方向进行分层处理，得到由一系列的XY二维平面组成的分层轮廓数据。 (2) composite forming process and control methods and SL and FDM process as complex forming process first need to create a three-dimensional CAD model of the target entity prototypes and slicing the model in the Z-axis direction, obtained from a series of XY hierarchical outline data consisting of a two-dimensional plane.

其次，对于SL和FDM工艺而言，都需要进行分层轮廓的内部填充，其中FDM只需进行X方向或Y方向的单向填充，而SL则需进行X方向-Y方向的双向填充以形成十字网格。 Secondly, SL and FDM process, the need to be filled with stratified internal contour, wherein the one-way filling FDM only X direction or the Y direction, and the need for two-way filling SL X direction in the -Y direction to form Cross grid. 所以，复合成形工艺需要根据SL和FDM各自的工艺特点，即FDM适宜成形内部大块区域，SL适宜成形外部精细轮廓，按照合适的区域划分策略，把每层轮廓内部区域划分为SL填充区域和FDM填充区域，如图5所示；然后针对SL填充区域生成双向填充线数据，针对FDM填充区域生成单向填充线数据。 Therefore, the composite molding process requires its own process characteristics according to SL and FDM, that is suitable for forming internal FDM large area, SL suitable for forming the outer contour of the fine, in accordance with the appropriate zoning policies, the internal area of ​​each contour is divided into regions and fill SL FDM fill area, as shown in Figure 5; then generated for the bidirectional data line SL is filled fill area, line data is generated for the one-way filling FDM fill area.

将上面生成的实体分层轮廓数据和内部填充线数据转化成数控数据，即可驱动快速成形执行机构进行分层制作。 The entity layered contour data generated above the fill line and the internal data into numerical data, you can drive rapid prototyping actuators stratified production.

在制作过程中，通过合理的成形过程控制方法保证复合成形工艺流程的实现。 In the production process, to ensure that the process of forming the composite molding process through reasonable control methods. 首先确定每层制作中SL和FDM工艺的启动次序，例如每层先进行FDM制作，然后进行SL制作；然后采用图6所示的控制系统，根据该次序控制成形头自动切换系统选取第一种成形头成形该区域薄层；再控制成形头自动切换系统切换第二种成形头成形该区域薄层；在成形不同区域之间的界面时，通过相应的控制策略来调节热量输出，以增强界面的再交联；如此分区域成形一层实体薄片后，控制Z向升降平台运动，制作下一层；逐层复合成形，最后制作出要求的三维实体。 First, determine the start order in each production SL and FDM technology, such as FDM each were produced before then SL production; then using the control system shown in Figure 6, the system automatically switches to select the first order under the control of the forming head forming a thin layer in the region forming head; then forming head control system automatically switches the second switching thin layer in the region forming the forming head; when forming the interface between different areas, by corresponding control strategy to adjust the heat output, in order to enhance the interface re-cross-linking; so subregional entities forming thin layer, the control Z motion to lift platform, produced under a layer; forming a composite layer by layer, and finally to produce a three-dimensional solid requirements.

根据上述发明构思，本发明采用的技术方案是：一种光固化与熔融沉积集成的复合快速成形方法，包括光固化成形法和熔融沉积成形法，其特征在于由所述的光固化成形法进行成形外部精细的轮廓，而由所述的熔融沉积成形法进行成形内部大块区域。 According to the inventive concept, the technical aspect of the present invention uses: a light-cured composite integrated with fused deposition rapid prototyping methods, including photo-curable molding and fused deposition molding, characterized by said light-curing molding method forming the outer contour of the fine, but by the Fused Deposition Modeling method of forming large area inside.

上述的复合快速成形方法的操作步骤如下：(1)建立数控数据：①建立目标实体原型件的三维CAD模型；②对上述模型进行分层处理，得到由一系列的XY二维平面组成的分层轮廓数据；③对各分层轮廓划分出外部精细轮廓区域和内部大块填充区域；④对上述的外部精细轮廓区域给出X方向-Y方向的双向十字形网格填充线数据，而对上述的内部大块填充区域给出X方向或Y方向的单向填充线数据。 Steps above composite rapid prototyping method is as follows: (1) the establishment of NC data: ① build a 3D CAD model of the target entity prototypes; ② slicing the above model, obtained from a series of two-dimensional XY plane consisting of points layer contour data; ③ hierarchical outline for each divided into external and internal chunk fine contour area filled areas; ④ above the external contour of the area gives a fine two-way cross X direction -Y data grid filling line direction, while said inner fill area is given chunk X direction or Y direction unidirectional fill line data.

(2)制作过程：据上述数控数据，作如下成形制作：①在基础平台上，先从最下层开始，先采用熔融沉积法对最下层的内部大块填充区域进行熔融沉积成形，然后使光固化液体与已填充区域齐平，在光固化液体中对最下层的外部精细轮廓区域进行光固化成形；②对最下第二层先采用熔融沉积法对该层的内部大块填充区进行熔融沉积成形，然后下降—上升基础平台，使光固化液体与新的已填充区域齐平，在光固化液体中对最下第二层的外部精细轮廓区域进行光固化成形。 (2) Production process: According to the above numerical data, as follows molding production: ① on the base platform, starting with the lowest level begin, fused deposition method using the lowest level of internal chunk filling area Fused Deposition Modeling, and then the light curing liquid filled area flush, in light curing liquid external contour of the region's most sophisticated light curing forming lower; ② most the second layer to the layer deposition method using molten interior filled with chunks of molten zone Deposition Modeling, then down - up the basic platform, the light-curable liquid filled the area with the new flush light curing liquid on the second floor of the outer most sophisticated light-cured molded contour area.

以上述方式逐层进行成形直至最上层而完成整体成形。 In the above-described manner until the uppermost layer by layer is molded integrally molded is completed.

一种上述光固化与熔融沉积集成的复合快速成形方法用的装置，包括一个光固化成形系统和一个熔融沉积成形系统，其特征在于所述的光固化成形系统与熔融沉积成形系统之间有一个成形头自动切换系统，由一个微机控制系统协同数控光固化成形系统和熔融沉积成形系统以及该两系统之间成形头的自动切换。 An above-mentioned photocurable and fused deposition rapid prototyping method integrated with a composite apparatus, comprising a light curing system and a fused deposition molding forming system, characterized in that there is a forming system between said photocurable and Fused Deposition Modeling system forming head automatic switching system, coordinated by a microcomputer control system CNC shaping light curing systems and fused deposition modeling forming head between the two systems, and the system automatically switches.

上述的熔融沉积成形系统的结构是：有一个成形槽12，其上设置X轴运动支架9，X轴运动支架9上设置Y轴运动支架8，在Y轴运动支架上设置成形头自动切换系统7，一个熔融丝材送丝机构6将熔融丝材5送至熔融沉积成形喷头4，该成形喷头4未工作时处于成形槽12右上角的熔融沉积成形喷头搁置位置14上，由微机控制系统控制而工作时自动切换到成形头自动切换系统7的启闭夹子中；所述的光固化成形系统的结构是：在上述的成形槽12中盛有光固化液15，成形槽12中设有供分层成形用的升降基础平台11，一个光源1经光纤光路系统2连接光聚焦头3，该光聚焦头未工作时处于成形槽12左上角的光聚焦头搁置位置13上，由微机控制系统控制而工作时自动切换到成形头自动切换系统7的启闭夹子中。 Structure of the above fused deposition modeling system are: a molding groove 12, on which the X-axis movement of the carriage 9, X-axis movement of the holder 8 disposed on the Y-axis movement of the carriage 9 provided on the forming head in the Y-axis movement of the holder automatic switching system 7, a melted wire wire feeding mechanism 6 will melt the wire 5 to the Fused Deposition Modeling nozzle 4, which is in the shape fused deposition nozzle 4 is not working right corner of the molding grooves 12 formed on the nozzle resting position 14, by microcomputer control system When the control is automatically switched to the working head of automatic switching open and close the clip forming system 7; photocurable forming system according to the structure: In the above molding groove 12 盛有光 solidifying liquid 15, the molding groove 12 is provided lifting platform forming the basis for the layered with 11 a light source through a fiber optical system 2 connects the optical focusing head 3, when the light is focused on the head does not work in the upper left corner of the molding grooves 12 on the light focusing head resting position 13, by computer control When the work control system automatically switches to open and close the clip forming head automatic switching system 7.

本发明与已有技术相比较，具有如下显而易见的突出实质性特点和显著优点：从成形机理来看，光固化(SL)方法采用激光等紫外光成形，而熔融沉积方法(FDM)采用热能成形，前者成形精度高，制作细节能力强，原型件表面质量好，但可用材料有限，制件力学和机械性能差，而且成本较高；后者可选用材料范围广，原型件性能好，制作成本也较低，但精度和表面质量较差。 The present invention and the prior art, compared with a prominent substantive features and notable advantages are obvious: the forming mechanism, the light-cured (SL) method using ultraviolet laser forming, and fused deposition method (FDM) using thermal forming The former high precision molding, making the details of ability, good surface quality prototypes, but the limited material available, the difference between the mechanical parts and mechanical properties, and high cost; wide range of materials which can be used, good performance prototypes, production costs lower, but poor precision and surface quality. 这两类成形工艺在制作能力和制件性能方面各有所长，互补性强，因此本发明采用集成方法，与原有的SL和FDM工艺方法相比，具有以下优点：(1)用FDM的低成本材料成形内部大块区域，用SL光敏树脂材料成形外部精细轮廓，可以有效降低材料成本；(2)由于复合成形过程的大部分时间采用FDM常规热源，大大降低了昂贵的激光器使用时间，所以有效降低了设备使用成本；(3)由于FDM成形效率较高，所以原型件的复合成形效率比SL工艺方法有大幅提高；(4)由于外部轮廓采用SL成形，而成形精度较差的FDM材料局限在原型件内部，所以原型件保持了SL的原有精度和表面质量，而比FDM提高很多；(5)由于原型件内部主要采用性能较好的FDM材料，所以整个原型件的力学和机械性能比SL有很大改善；(6)虽然在原型件内部不同成形区域结合界面处的材料在复杂的物理、化学反应下形成的精度、粗糙度很差，但由于局限在原型件的内部，不影响轮廓表面质量；(7)由于SL和FDM工艺采用不同的材料成形，所以这种复合成形方法自然实现了材料的集成，可以制作多材料相原型件，并可通过材料的选择实现其性能的分区域定制，这是快速成形方法与其它传统工艺(如车削、铣削、磨削等)集成所不能实现的。 These two types of forming processes in the production capacity and performance parts strengths are highly complementary, and therefore the present invention is an integrated method, compared to the original SL and FDM process method has the following advantages: (1) FDM The large area of ​​low-cost materials forming the interior, forming an external contour with fine SL photosensitive resin material, can effectively reduce the material cost; (2) Since most of the composite forming process using conventional FDM heat, greatly reduces the usage time of expensive lasers , so effectively reducing the equipment cost; (3) due to the higher efficiency FDM molding, so the efficiency of the prototype member of the compound forming a substantial improvement over SL process method; (4) due to the use of the outer contour of SL molding, and poor forming precision FDM prototypes within the limitations of the material, so keep the original prototypes accuracy and surface quality SL, and to improve a lot more than FDM; (5) mainly due to internal prototypes better performance FDM materials, so the entire mechanical prototypes and mechanical properties have greatly improved over SL; precision (6) Although the bonding interface prototypes internally in different materials forming region in a complex physical and chemical reactions, the roughness of the poor, but because of the limitations in the prototype parts internally, does not affect the surface quality of the contour; (7) Since the SL and FDM molding process using different materials, so this method of molding a composite material to achieve the integration of natural, can produce multi-material phase prototype member, and through the choice of materials to achieve Subregional customize its performance, which is integrated with other rapid prototyping methods of traditional crafts (such as turning, milling, grinding, etc.) can not be achieved.

综上所述，本发明可集成SL和FDM优点，在精度、效率、成本、原型件表面质量及性能等多方面优势互补，从而实现RPM技术综合性能的整体提高，高效低成本地制作高性能原型件。 In summary, the present invention can be integrated SL and FDM advantages complementary in accuracy, efficiency, cost, quality and performance of the prototype surface and many other advantages, in order to achieve the overall improvement of the overall performance of RPM technology, efficient production of high performance at low cost prototypes.

本发明适用于检测用具、模具、美学制品、医学机械等精密件的制造。 The present invention is applicable to manufacturing test equipment, molds, aesthetic products, medical machinery and other precision parts.