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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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圖 1 電場驅動熔融噴射沉積高分辨率3D打印系統基本原理示意圖
Figure 1. Diagram of the basic principles of high-resolution fused deposition 3D printing based on electric-field-driven jetting system
圖 2 脈沖錐射流和連續錐射流兩種打印模式成形原理和受力狀態示意圖. (a) 脈沖錐射流模; (b) 連續錐射流模
Figure 2. Diagram of the formation principle and force state of the pulsed-cone and continuous-cone jet printing modes: (a) pulsed cone-jet mode; (b) continuous cone-jet mode
圖 3 電場驅動熱熔融噴射沉積高分辨率3D打印電場和溫度場仿真圖. (a) 電場分布和強度; (b) 溫度變化
Figure 3. Simulation of electric and temperature fields of high-resolution fused deposition 3D printing: (a) electric field distribution and strength; (b) temperature change
圖 4 電場驅動熔融噴射沉積高分辨率3D打印實驗裝置照片
Figure 4. Experimental setup of high-resolution fused deposition 3D printing based on electric-field-driven jetting
圖 5 噴嘴處熔滴動態演化和噴射示意圖. (a~c) 連續錐射流模式; (d~f) 脈沖錐射流模式
Figure 5. Images of dynamic evolution and injection of droplets at the nozzle: (a-c) continuous cone-jet mode; (d-f) pulsed cone-jet mode
圖 6 電壓對于打印線圖案的影響和規律
Figure 6. Influence and rule of voltage for the print line pattern
圖 7 工作臺速度對于打印線圖案的影響和規律
Figure 7. Influence and rule of stage speed for the print line pattern
圖 9 脈沖錐射流打印模式打印微晶蠟點陣列和圖案
Figure 9. Dot arrays and patterns of microcrystalline wax printed using the pulsed-cone jet printing mode
圖 10 大尺寸微尺度線柵結構模具. (a) 宏觀結構; (b) 微觀結構; (c) 單線三維結構
Figure 10. Large micro-scale wire-grid structure mold: (a) macrostructure; (b) micro structure; (c) single-line three-dimensional structure
圖 11 打印的大高寬比微尺度“墻”結構(線寬50 μm，高寬比10∶1). (a) 俯視圖; (b) 前視圖
Figure 11. Micro-scale "wall" structure with a large aspect ratio (line width 50 μm; aspect ratio 10∶1): (a) top view; (b) front view
圖 12 打印的大高寬比微尺度圓環(壁厚20 μm，直徑20 mm，高度500 μm，高寬比25∶1). (a) 宏觀結構; (b) 微觀結構
Figure 12. Microscale ring with a large aspect ratio (wall thickness 20 μm; diameter 20 mm; height 500 μm; aspect ratio 25∶1): (a) macrostructure; (b) micro structure
圖 13 電場驅動熔融噴射沉積高分辨率3D打印的組織支架和網格三維結構. (a) 組織支架; (b) 網格三維結構
Figure 13. Fabrication of tissue scaffold and three-dimensional grid structure using the high-resolution fused deposition 3D printing method based on electric-field-driven jetting system: (a) tissue scaffold; (b) three-dimensional grid structure
表 1 聚己內酯(PCL)材料性能參數
Table 1. Performance parameters of polycaprolactone (PCL) material
性能參數 數值 分子量 40000 密度(25 ℃)/(g·mL-1) 1.146 熔點/℃ 59~64 熔融黏度/(dL·g-1) 11.25 熔融指數范圍(每10 min)/g 7.3~28 
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表 2 石蠟(80號微晶蠟)材料性能參數
Table 2. Performance parameters of paraffin wax (80 microcrystalline wax)
性能參數 數據 分子量 650 密度/(g·mL-1) 0.80~0.92 熔點/℃ 72~82 熔融黏度/(mm2·s-1) 10~20 熔融指數范圍
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