3D printer based on liquid-solid chemical reaction deposition and operating methods thereof

Patent metadata

Field	Value
Publication number	US-11969944-B2
Application number	US-201816962543-A
Country	US
Kind code	B2
Filing date	Oct 25, 2018
Priority date	Jan 17, 2018
Publication date	Apr 30, 2024
Grant date	Apr 30, 2024

Abstract

The invention discloses a 3D printer based on liquid-solid chemical reaction deposition and operating methods thereof, comprising a sealed forming chamber, a powder container, a forming container, a powder spreading mechanism, and a three-axis linkage mechanism in the sealed forming chamber. The three-axis linkage mechanism moves a nozzle in the sealed forming chamber according to a movement path planning of a control system of the 3D printer. A liquid supply device is provided outside the sealed forming chamber. The liquid supply device contains a gel-like reactant. The nozzle is a liquid nozzle. The liquid nozzle communicates with the liquid supply device through a following conduit. Through the phenomenon of solid deposition produced by chemical reaction between gel-like reactant and powder substance, following the digital model of the required part, and according to the processed movement path, the liquid nozzle is controlled to move in a selected area and continuously ejects gel-like reactant to have chemical deposition reaction with base powder substance. After layer-by-layer cumulative stacking with existing 3D printing additive manufacturing equipment, and after solidification, the entire part is finally formed.

First claim

The invention claimed is:

1. A 3D printer based on liquid-solid chemical reaction deposition, comprising a sealed forming chamber ( 8 ), a powder container ( 14 ), a forming container ( 16 ), a powder spreading mechanism, and a three-axis linkage mechanism in the sealed forming chamber ( 8 ); the three-axis linkage mechanism moves a nozzle along a X-axis, Y-axis, or Z-axis direction in the sealed forming chamber ( 8 ) according to a movement path planning of a control system of the 3D printer; characterised in that, a liquid supply device ( 1 ) is provided outside the sealed forming chamber ( 8 ), the liquid supply device ( 1 ) contains a gel reactant ( 3 ); the nozzle is a liquid nozzle ( 13 ); the liquid nozzle ( 13 ) communicates with the liquid supply device ( 1 ) through a following conduit ( 4 ); during an operation, the liquid supply device ( 1 ) delivers the gel reactant ( 3 ) therein to the liquid nozzle ( 13 ) through the following conduit ( 4 );
wherein the powder container ( 14 ) contains a base powder substance which chemically reacts with the gel reactant ( 3 ) to deposit to complete a processing of a formed layer;
wherein the gel reactant ( 3 ) is a liquid gel reactant, and the liquid gel reactant is calcium chloride gel or barium chloride gel;
wherein the base powder substance is powder, and the powder is sodium carbonate powder or sodium sulphate powder; and
wherein the base powder substance is adapted for chemical precipitation reaction with the gel reactant ( 3 ) to produce a solid precipitate.

2. The 3D printer based on liquid-solid chemical reaction deposition according to claim 1 , characterized in that, a junction of the following conduit ( 4 ) and the liquid supply device ( 1 ) is provided with a solenoid valve ( 5 ).

3. The 3D printer based on liquid-solid chemical reaction deposition according to claim 1 , characterized in that, a base plate is provided inside the forming container ( 16 ), the base plate is driven up and down by a screw mechanism at the bottom thereof.

4. The 3D printer based on liquid-solid chemical reaction deposition according to claim 3 , characterized in that, a powder collecting container ( 18 ) is provided on a right side of the forming container ( 16 ).

5. An operating method based on liquid-solid chemical reaction deposition, characterized in that, the method is implemented using the 3D printer based on liquid-solid chemical reaction deposition as claimed in claim 4 , the method comprising the following steps:
step 1: creating a three-dimensional digital model based on a shape of a part to be processed, and then saving it in a STL format file; using slicing software to slice the three-dimensional digital model; a thickness of each slice is the same; and the slices contain profile information of the part; importing a file after slicing into movement path planning software to obtain moving path data of the liquid nozzle ( 13 );
step 2: preparing the gel-like reactant ( 3 ) and base powder substance then setting a flow rate of the gel-like reactant ( 3 ) through a solenoid valve ( 5 ), and finally placing the gel-like reactant ( 3 ) and the base powder substance in a liquid supply tank of the liquid supply device ( 1 ) and in the powder container ( 14 ) respectively;
step 3: adjusting coordinate positions of the liquid nozzle ( 13 ) through the three-axis linkage mechanism; moving the nozzle of the liquid nozzle ( 13 ) to on top of the base plate of the forming container ( 16 ) in advance, at a slice thickness away from the base plate;
step 4: starting a processing operation; the three-axis linkage mechanism carries the liquid nozzle ( 13 ) according to the movement path planning of the control system of the 3D printer to follow the movement path data in step 1 to selectively spray the gel-like reactant ( 3 ) on the base plate; the gel-like reactant ( 3 ) in contact with the base powder substance reacts chemically and deposit to complete a processing of a formed layer of the part;
step 5: after completing step 4, lowering the forming base by a height of the slice thickness; raising powder of the powder container ( 14 ) by the height of a slice; driven by the powder brush ( 12 ) of the powder spreading mechanism, covering a surface of the formed layer with the base powder substance again to form a new base powder substance layer; the liquid nozzle ( 13 ) follows a movement path of a next layer; spraying the gel-like reactant ( 3 ) onto the new base powder substance layer on the surface of the formed layer; through a chemical reaction of the gel-like reactant ( 3 ) with the new base powder substance layer, generated substance is deposited on the surface of the formed layer to complete a processing of another formed layer of the part;
step 6: repeating steps 4 to 5 until the entire processing of the part is completed.

Assignees

• Univ South China Tech

Inventors

• Yang Yongqiang
• Bai Yuchao

Classifications

• B29C64/321 Primary

  Feeding · CPC title

• B22F1/10

  Metallic powder containing lubricating or binding agents; Metallic powder containing organic material · CPC title

• B22F10/14

  by jetting of binder onto a bed of metal powder · CPC title

• B22F12/53

  Nozzles · CPC title

• B29C64/165

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title