Composite transparent film, preparation method thereof, and method for continuous digital light processing ceramic 3D printing based on the same

Patent metadata

Field	Value
Publication number	US-12090683-B2
Application number	US-202217568098-A
Country	US
Kind code	B2
Filing date	Jan 4, 2022
Priority date	Jan 5, 2021
Publication date	Sep 17, 2024
Grant date	Sep 17, 2024

Abstract

A composite transparent film, a preparation method thereof and a method for continuous digital light processing ceramic 3D printing based on the same are provided. The method selects a mixture of silica microspheres and PDMS to form a composite film on which silica is used to form a hydrophobic layer. Combined with specific optimized parameters, the film is more suitable for continuous digital light processing ceramic 3D printing, which can realize the continuous printing of ceramic slurries, solve the problem of delamination of printed pieces obtained by the existing 3D printing method of ceramics, improve the printing accuracy, and decrease the printing costs.

First claim

What is claimed is:

1. A method for preparing a composite transparent film for continuous digital light processing ceramic 3D printing, the method comprising steps of:
(1) taking a spherical SiO 2 particle with a particle size of about 200 nm and a premixed solution of PDMS, with a mass ratio of SiO 2 of 10%-40%, and stirring at 200 r/min-300 r/min for 2-5 min;
(2) mixing a mixed solution of step (1) in an ultrasonic cleaning machine for 15-20 min;
(3) adding a PDMS curing agent after standing and cooling, with the mass ratio of curing agent and a premixed solution of PDMS of 1/10-1/8, and stirring at 200 r/min-300 r/min for 3-5 min;
(4) standing for 12-24 h at a temperature of 0-8° C. until no bubbles;
(5) using a CNC engraving machine to print the mixed solution of step (4) into a film by baseboard heating at 80-100° C. under an air pressure of 30-50 kPa, and a speed of 320-400 mm/s;
(6) drying the printed film in a drying oven;
(7) immersing a fully cured SiO 2 /PDMS composite film into a container filled with a SiO 2 suspension, wherein the particle size of SiO 2 in the suspension is 2-5 μm, and pulling up vertically using a pulling machine at a uniform speed of 1-8 mm/s;
(8) heating the resulting composite film of step (7) at 200-250° C. for 60-80 h;
(9) spin-coating a photoresist SU-8-based epoxy resin into a gap between SiO 2 particles on a surface of the composite film using a spin coater for 30-60 s at a rotation speed of 2500-3500 r/min, and then using an organic solvent to clean a remaining photoresist on the surface;
(10) curing the photoresist on the surface using a UV curing lamp for 1-3 min; and
(11) etching the resulting composite film of step (10) in a hydrofluoric acid solution for 5-15 min to remove SiO 2 on the surface, cleaning thoroughly with alcohol, and drying in the drying oven.

2. The method for preparing the composite transparent film for continuous digital light processing ceramic 3D printing according to claim 1 , wherein the concentration of the hydrofluoric acid solution in the step (11) is 2-5 vol %.

3. The method for preparing the composite transparent film for continuous digital light processing ceramic 3D printing according to claim 1 , wherein;
in the step (6), the drying temperature is 80-100° C., and the drying time is 2-3 h; and
in the step (11), the temperature of the drying oven is 60-80° C., and the drying time is 2-5 h.

4. A method for continuous digital light processing ceramic 3D printing using the composite transparent film prepared by the method according to claim 1 , the composite transparent film having a thickness of 50-100 μm, an oxygen transmission efficiency of above 50 barrer, a ultraviolet light transmittance of not less than 80%, and an intensity of not less than 20 kPa; and the method for continuous digital light processing ceramic 3D printing comprising steps of:
(1) pouring a prepared ceramic slurry into a storage tank;
(2) controlling a bottom of printing platform at 20-30 μm above the composite transparent film, and making the slurry immerse the bottom of the platform;
(3) introducing cooling oxygen;
(4) turning on a light source to project a pre-processed image on the composite transparent film;
(5) after 10-15 s, controlling the printing platform to move upward at a constant speed of no more than 400 mm/h, and changing the projected image accordingly;
(6) after printing, turning off the light source, suspending the moving of printing platform, and stopping the introducing of cooling oxygen in sequence;
(7) taking down a green body for printing ceramics and cleaning off a micro-cured slurry residue;
(8) using a UV curing lamp to perform a secondary curing on the green body to finally obtain a required green body for printing ceramics; and
(9) sintering according to a corresponding sintering process to obtain a required ceramic.

5. The method for continuous digital light processing ceramic 3D printing according to claim 4 , wherein the ceramic is selected from one or more of zirconia, aluminum oxide, silicon nitride, magnesium oxide, and yttrium oxide.

6. The method for continuous digital light processing ceramic 3D printing according to claim 5 , wherein the average particle size is 0.5-5 μm, and the powder shape is polygonal or spherical.

7. The method for continuous digital light processing ceramic 3D printing according to claim 4 , wherein mixing the selected ceramic raw materials with a photosensitive resin, stirring manually at 200-300 r/min for 2-5 min, pouring into a ball mill, mixing at 300-450 r/min for 6-8 h, then placing the mixture in a drying oven and drying at room temperature for 60-90 min to obtain a required ceramic slurry.

8. The method for continuous digital light processing ceramic 3D printing according to claim 4 , wherein a device used in the method includes a workbench and a base, and the workbench includes a printing platform, a storage tank, a composite transparent film, an oxygen supply cooling module, and a digital light module from top to bottom.

Assignees

• Univ Qingdao Technology

Inventors

• Zhang Guangming
• Jiang Jin
• Lan Hongbo
• Wang Fei
• Song Daosen
• Huang Hui
• Li Wenhai
• Yu Zun

Classifications

• B28B13/0275

  Feeding a slurry or a ceramic slip · CPC title

• B28B1/008

  made from two or more materials having different characteristics or properties (casting for producing layered articles B28B1/16; feeding several succesive layers, optionally of different materials B28B13/022; coating B28B11/04; applying material to surfaces to form a permanent layer thereon B28B19/00) · CPC title

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title

• B33Y40/10

  Pre-treatment · CPC title

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title