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電場驅動熔融噴射沉積高分辨率3D打印

High-resolution fused deposition 3D printing based on electric-field-driven jet

  • 摘要: 針對傳統熔融沉積成型面臨的成型精度低和打印材料受限, 基于電流體動力熔融沉積在成形高度、材料種類、基板導電性和平整性、3D成形能力等方面的不足和局限性, 本研究提出一種電場驅動熔融噴射沉積3D打印新工藝, 其采用雙加熱集成式噴頭并施加單極脈沖高電壓(單電勢), 利用電場驅動微量熱熔融材料噴射并精準沉積來形成高分辨率結構.引入兩種新的打印模式: 脈沖錐射流模式和連續錐射流模式, 拓展了可供打印材料的種類和范圍.通過理論分析、數值模擬和實驗研究, 揭示了所提出工藝的成形機理、作用機制以及成形規律.利用提出的電場驅動熔融噴射沉積3D打印方法, 結合優化工藝參數, 完成了三個典型工程案例, 即大尺寸微尺度模具、大高寬比微結構、宏微跨尺度組織支架和網格三維結構.其中采用內徑250 μm噴頭, 打印出最小線寬4 μm線柵結構, 高寬比達到25:1薄壁圓環微結構.結果表明, 電場驅動熔融噴射沉積高分辨率3D打印具有打印分辨率高、材料普適性廣、宏/微跨尺度的突出優勢, 為實現低成本、高分辨率熔融沉積3D打印提供了一種全新的解決方案.

     

    Abstract: The existing fused deposition modeling (FDM) technique faces disadvantages of low resolution and limited printable materials; meanwhile the E-jet-based fused deposition method confronts limitations associated with the formation height, material type, conductivity, and flatness of the substrate, and the 3D forming ability. Herein, a new technology called electric-field-driven fused-jet deposition 3D printing was proposed. In the proposed technology, a dual-heated integrated nozzle connected to a single positive-pulse high voltage (single potential) was used to eject and precisely deposit a small amount of molten material to form a high-resolution structure based on the drive of the electric field force. Two novel printing modes, the continuous-cone and pulse-cone jet modes, were developed to broaden the range of printable materials using the proposed technique. The mechanism and rules of formation for the proposed process were systematically investigated via theoretical analysis, numerical simulation, and experimental verification. Using optimized process parameters and the proposed electric-field-driven fused-jet deposition 3D printing method, three typical cases, including a large micro-scale mold, a high-aspect-ratio micros-scale structure, a macro-micro-scale tissue scaffold, and a three-dimensional grid structure were fabricated. Outstanding results were obtained, including the printing of a wire grid structure with a minimum line width of 4 μm and a thin-walled ring microstructure with an aspect ratio of 25:1 using a nozzle with an inner diameter of 250 μm. The experimental results demonstrate that the proposed electric-field-driven fused-jet-deposition 3D printing method is a promising and effective method that meets the requirements of the high-resolution FDM process at low cost. The new technolgy proposed in this paper offers a novel solution for realizing high-resolution and macro/micro-scale fused-jet deposition 3D printing at low cost with good material universality.

     

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