3DP工艺中阶梯误差与渗透误差相互作用研究

3DP工艺中影响零件成型精度的原理性误差主要来源于阶梯误差和黏结剂渗透误差,并且在误差测量结果中难以区分.本文基于黏结剂在砂床中的流动状态,建立了黏结剂从喷射到渗透过程的数值仿真模型,分析了在二维平面不同角度三角面片打印时理想模型边界和实际黏结砂粒边界之间的位置误差,研究了阶梯误差和渗透误差之间的相互作用.在此基础上,针对不同角度三角面片打印过程中阶梯误差与黏结剂渗透误差相互作用关系也不相同的问题,提出了基于三角面片法向量方向与成型方向夹角的三角面片偏移误差公式用于表达这两种误差对成型质量的综合影响.结果表明:在向上三角面片中,渗透误差与阶梯误差相互补偿,三角面片偏移误差随着斜面与水平面夹角角度的减小而减小;在向下三角面片中,阶梯误差与渗透误差相互叠加,三角面片偏移误差随着斜面与水平面夹角角度的减小而增大.将三角面片偏移误差的公式计算值与其实际测量值进行对比,公式计算误差最大为0.060 mm,最小为0.002 mm,表明三角面片偏移误差公式用于表达阶梯误差与黏结剂渗透误差综合作用的有效性.

木塑材料3DP打印机运动控制系统轨迹跟踪研究

针对木塑材料3DP打印机运动控制系统X轴负载较大而导致CoreXY机构在进行开环控制时打印精度较差的问题,研究3DP打印机的模型预测控制(MPC)智能轨迹跟踪算法,提高打印精度和打印速度。基于黏结剂喷射(3DP)成型工艺和CoreXY机构的传动特点设计了木塑材料3DP打印机运动控制系统,提出了一种适用于3DP打印机的MPC轨迹跟踪策略。采用笛卡尔坐标系下近似圆形切片的打印轨迹作为参考轨迹,建立CoreXY机构A、B电机闭环系统的预测模型,运用MPC理论将打印速度和精度的多约束最优控制问题变为带约束的二次函数进行求解,对比参考轨迹与实际打印轨迹之间的误差,进而研究不同打印速度对轨迹跟踪效果的影响。对仿真结果进行分析计算得出,打印速度在80~400 mm/s范围内,3DP打印机的喷胶位点均可实现对参考轨迹的较准确跟踪,A、B电机皮带位移最大横向误差分别为0.0097和0.0060 mm,X、Y轴横向误差的平均绝对误差分别为0.357和0.362 mm。对比PID控制,MPC控制策略的各项衡量指标都更优,且参数更易整定,横向误差更小,提高了3DP打印机喷射路径的准确度和效率。随着打印速度的降低,MPC控制器的横向误差逐渐减小,系统的轨迹跟踪效果更准确和稳定,最终绘制参考轨迹与实际轨迹形状基本重合。

木塑复合材料3DP设备微滴喷射过程仿真及关键参数研究

【目的】以自主研发的木塑复合材料三维打印与胶黏(3DP)微滴喷射系统为基础,开展紫外线固化黏结剂(UV胶)微滴喷射过程的研究,优化喷射系统工艺参数和阀体结构参数,为木塑复合材料3DP工艺液滴铺展渗透研究提供数据支撑。【方法】对喷射阀撞针的位移特征、UV胶的流变特性进行测定分析,确定了影响木塑复合材料3DP设备微滴喷射过程的喷射参数。采用有限元法对微滴喷射过程进行仿真,分析了微滴喷射过程中UV胶在喷嘴处速度、压力和质量流率的变化特征,获得了喷射参数对微滴喷射过程的影响规律。选取撞针速度、喷嘴直径、供胶压力为自变量,以液滴成形质量和主液滴速度为评价指标,开展仿真试验求解优化参数组。【结果】单因素试验得到了撞针速度0.3~0.9 m·s^(−1),喷嘴直径0.10~0.20 mm,供胶压力0.1~0.3 MPa,阀座锥角120°~130°的合理喷射参数范围。正交试验得到了喷嘴直径是影响液滴质量的显著因素,供胶压力是影响液滴速度的显著因素,并获得最优的喷射参数组合为喷嘴直径0.10 mm,撞针速度0.9 m·s^(−1),供胶压力0.1 MPa、阀座锥角130°。【结论】建立了基于木塑复合材料3DP微滴喷射过程的VOF有限元模型,完成了喷射参数对微滴喷射影响的研究,获得了最优的喷射参数组合。

Method of fabricating artificial rock specimens based on extrusion free forming(EFF)3D printing

Three-dimensional(3D)printing technology has been widely used to create artificial rock samples in rock mechanics.While 3D printing can create complex fractures,the material still lacks sufficient similarity to natural rock.Extrusion free forming(EFF)is a 3D printing technique that uses clay as the printing material and cures the specimens through high-temperature sintering.In this study,we attempted to use the EFF technology to fabricate artificial rock specimens.The results show the physico-mechanical properties of the specimens are significantly affected by the sintering temperature,while the nozzle diameter and layer thickness also have a certain impact.The specimens are primarily composed of SiO_(2),with mineral compositions similar to that of natural rocks.The density,uniaxial compressive strength(UCS),elastic modulus,and tensile strength of the printed specimens fall in the range of 1.65–2.54 g/cm3,16.46–50.49 MPa,2.17–13.35 GPa,and 0.82–17.18 MPa,respectively.It is capable of simulating different types of rocks,especially mudstone,sandstone,limestone,and gneiss.However,the simulation of hard rocks with UCS exceeding 50 MPa still requires validation.

Cookie Baking Process Optimization and Quality Analysis Based on Food 3D Printing

In order to obtain better quality cookies, food 3D printing technology was employed to prepare cookies. The texture, color, deformation, moisture content, and temperature of the cookie as evaluation indicators, the influences of baking process parameters, such as baking time, surface heating temperature and bottom heating temperature, on the quality of the cookie were studied to optimize the baking process parameters. The results showed that the baking process parameters had obvious effects on the texture, color, deformation, moisture content, and temperature of the cookie. All of the roasting surface heating temperature, bottom heating temperature and baking time had positive influences on the hardness, crunchiness, crispiness, and the total color difference(ΔE) of the cookie. When the heating temperatures of the surfac and bottom increased, the diameter and thickness deformation rate of the cookie increased. However,with the extension of baking time, the diameter and thickness deformation rate of the cookie first increased and then decreased. With the surface heating temperature of 180 ℃, the bottom heating temperature of 150 ℃, and baking time of 15 min, the cookie was crisp and moderate with moderate deformation and uniform color. There was no burnt phenomenon with the desired quality. Research results provided a theoretical basis for cookie manufactory based on food 3D printing technology.

3DP打印砂型(芯)的研究及应用进展

与传统工艺相比,三维喷印技术(3DP)打印砂型(芯)在铸造工艺开发或复杂铸件的单件小批量生产时,优势明显且极具发展潜力。近年来,3DP在砂型铸造领域的研究和应用发展迅速,成为备受关注的热点。本文对3DP进行了介绍,综述了3DP打印砂型(芯)的研究和应用现状,并对存在的问题及研发应用前景进行了探讨。

Application and prospects of 3D printing in physical experiments of rock mass mechanics and engineering:materials,methodologies and models

The existence of joints or other kinds of discontinuities has a dramatic efect on the stability of rock excavations and engineering.As a result,a great challenge in rock mass mechanics testing is to prepare rock or rock-like samples with defects.In recent years,3D printing technology has become a promising tool in the feld of rock mass mechanics and engineering.This study frst reviews and discusses the research status of traditional test methods in rock mass mechanics tests of making rock samples with defects.Then,based on the comprehensive analysis of previous research,the application of 3D printing technology in rock mass mechanics is expounded from the following three aspects.The frst is the printing material.Although there are many materials for 3D printing,it has been found that 3D printing materials that can be used for rock mass mechanics research are very limited.After research,we summarize and evaluate printing material that can be used for rock mass mechanics studies.The second is the printing methodology,which mainly introduces the current application forms of 3D printing technology in rock mass mechanics.This includes printed precise casting molds and one-time printed samples.The last one is the printing model,which includes small-scale samples for mechanical tests and large-scale physical models.Then,the benefts and drawbacks of using 3D printing samples in mechanical tests and the validity of their simulation of real rock are discussed.Compared with traditional rock samples collected in nature or synthetic rock-like samples,the samples made by 3D printing technology have unique advantages,such as higher test repeatability,visualization of rock internal structure and stress distribution.There is thus great potential for the use of 3D printing in the feld of rock mass mechanics.However,3D printing materials also have shortcomings,such as insufcient material strength and accuracy at this stage.Finally,the application prospect of 3D printing technology in rock mass mechanics research is proposed.

Recent advances in meniscus-on-demand three-dimensional micro-and nano-printing for electronics and photonics

The continual demand for modern optoelectronics with a high integration degree and customized functions has increased requirements for nanofabrication methods with high resolution,freeform,and mask-free.Meniscus-on-demand three-dimensional(3D)printing is a high-resolution additive manufacturing technique that exploits the ink meniscus formed on a printer nozzle and is suitable for the fabrication of micro/nanoscale 3D architectures.This method can be used for solution-processed 3D patterning of materials at a resolution of up to100 nm,which provides an excellent platform for fundamental scientific studies and various practical applications.This review presents recent advances in meniscus-on-demand 3D printing,together with historical perspectives and theoretical background on meniscus formation and stability.Moreover,this review highlights the capabilities of meniscus-on-demand 3D printing in terms of printable materials and potential areas of application,such as electronics and photonics.

Method for visualizing the shear process of rock joints using 3D laser scanning and 3D printing techniques

This study presents a visualized approach for tracking joint surface morphology.Three-dimensional laser scanning(3DLS)and 3D printing(3DP)techniques are adopted to record progressive failure during rock joint shearing.The 3DP resin is used to create transparent specimens to reproduce the surface morphology of a natural joint precisely.The freezing method is employed to enhance the mechanical properties of the 3DP specimens to reproduce the properties of hard rock more accurately.A video camera containing a charge-coupled device(CCD)camera is utilized to record the evolution of damaged area of joint surface during the direct shear test.The optimal shooting distance and shooting angle are recommended to be 800 mm and 40?,respectively.The images captured by the CCD camera are corrected to quantitatively describe the damaged area on the joint surface.Verification indicates that this method can accurately describe the total sheared areas at different shear stages.These findings may contribute to elucidating the shear behavior of rock joints.

4D printing: interdisciplinary integration of smart materials, structural design,and new functionality

Four-dimensional printing allows for the transformation capabilities of 3D-printed architectures over time,altering their shape,properties,or function when exposed to external stimuli.This interdisciplinary technology endows the 3D architectures with unique functionalities,which has generated excitement in diverse research fields,such as soft robotics,biomimetics,biomedical devices,and sensors.Understanding the selection of the material,architectural designs,and employed stimuli is crucial to unlocking the potential of smart customization with 4D printing.This review summarizes recent significant developments in 4D printing and establishes links between smart materials,3D printing techniques,programmable structures,diversiform stimulus,and new functionalities for multidisciplinary applications.We start by introducing the advanced features of 4D printing and the key technological roadmap for its implementation.We then place considerable emphasis on printable smart materials and structural designs,as well as general approaches to designing programmable structures.We also review stimulus designs in smart materials and their associated stimulus-responsive mechanisms.Finally,we discuss new functionalities of 4D printing for potential applications and further development directions.

A Generalized Polymer Precursor Ink Design for 3D Printing of Functional Metal Oxides

Three-dimensional-structured metal oxides have myriad applications for optoelectronic devices.Comparing to conventional lithography-based manufacturing methods which face significant challenges for 3D device architectures,additive manufacturing approaches such as direct ink writing offer convenient,on-demand manufacturing of 3D oxides with high resolutions down to sub-micrometer scales.However,the lack of a universal ink design strategy greatly limits the choices of printable oxides.Here,a universal,facile synthetic strategy is developed for direct ink writable polymer precursor inks based on metal-polymer coordination effect.Specifically,polyethyleneimine functionalized by ethylenediaminetetraacetic acid is employed as the polymer matrix for adsorbing targeted metal ions.Next,glucose is introduced as a crosslinker for endowing the polymer precursor inks with a thermosetting property required for 3D printing via the Maillard reaction.For demonstrations,binary(i.e.,ZnO,CuO,In_(2)O_(3),Ga_(2)O_(3),TiO_(2),and Y_(2)O_(3)) and ternary metal oxides(i.e.,BaTiO_(3) and SrTiO_(3)) are printed into 3D architectures with sub-micrometer resolution by extruding the inks through ultrafine nozzles.Upon thermal crosslinking and pyrolysis,the 3D microarchitectures with woodpile geometries exhibit strong light-matter coupling in the mid-infrared region.The design strategy for printable inks opens a new pathway toward 3D-printed optoelectronic devices based on functional oxides.

Effect of sintering temperature on microstructure and properties of 3D printing polysilazane reinforced Al_(2)O_(3)core

Ceramic cores are the key intermediate components of hollow blades for aero-engine.Conventional processes,such as hot-press molding and gel film casting,face difficulties in fabricating complex-structured ceramic cores due to the complexity of moulds and long process cycles.Stereolithography 3D printing provides a new idea for the fabrication of complex-structured ceramic cores.The effect of sintering temperature on open porosity,bulk density,weight loss rate,shrinkage rate,flexural strength and microstructure of the Al_(2)O_(3)-based ceramic core doped with 10vol.%polysilazane(PSZ)was studied.The sintering mechanism of PSZ-reinforced ceramic cores was analyzed.Results show that the optimum sintering temperature of PSZ-reinforced ceramic cores is 1,450°C.At this temperature,the open porosity of the ceramic core is 36.60%,bulk density is 2.33 g·cm^(-3),weight loss rate is 22.11%,shrinkage rate along the X,Y,Z directions is 5.72%,5.01%,9.61%,respectively;the flexural strength is 28.794 MPa at 25°C and 13.649 MPa at 1,500°C.Properties of 3D printing PSZ-reinforced ceramic cores can meet the casting requirement of superalloy hollow blades,which is expected to promote the industrial application of 3D printing complex structure ceramic cores.

Effect of surface retaining elements on rock stability:laboratory investigation with sand powder 3D printing

This study aims to investigate the benefcial efects of surface retaining elements (SREs) on the mechanical behaviors of bolted rock and roadway stability. 3D printing (3DP) technology is utilized to create rock analogue prismatic specimens for conducting this investigation. Uniaxial compression tests with acoustic emission (AE) and digital image correlation techniques have been conducted on 3DP specimens bolted with diferent SREs. The results demonstrate that the strength and modulus of elasticity of the bolted specimens show a positive correlation with the area of the SRE;the AE characteristics of the bolted specimens are higher than those of the unbolted specimen, but they decrease with an increase in SRE area, thus further improving the integrity of the bolted specimens. The reinforcement efect of SREs on the surrounding rock of roadways is further analyzed using numerical modelling and feld test. The results provide a better understanding of the role of SREs in rock bolting and the optimization of rock bolting design. Furthermore, they verify the feasibility of 3DP for rock analogues in rock mechanics tests.

3D printing of high-precision and ferromagnetic functional devices

The development of projection-based stereolithography additive manufacturing techniques and magnetic photosensitive resins has provided a powerful approach to fabricate miniaturized magnetic functional devices with complex three-dimensional spatial structures.However,the present magnetic photosensitive resins face great challenges in the trade-off between high ferromagnetism and excellent printing quality.To address these challenges,we develop a novel NdFeB-Fe_(3)O_(4) magnetic photosensitive resin comprising 20 wt.%solid loading of magnetic particles,which can be used to fabricate high-precision and ferromagnetic functional devices via micro-continuous liquid interface production process.This resin combining ferromagnetic NdFeB microparticles and strongly absorbing Fe_(3)O_(4) nanoparticles is able to provide ferromagnetic capabilities and excellent printing quality simultaneously compared to both existing soft and hard magnetic photosensitive resins.The established penetration depth model reveals the effect of particle size,solid loading,and absorbance on the curing characteristics of magnetic photosensitive resin.A high-precision forming and ferromagnetic capability of the NdFeB-Fe_(3)O_(4) magnetic photosensitive resin are comprehensively demonstrated.It is found that the photosensitive resin(NdFeB:Fe_(3)O_(4)=1:1)can print samples with sub-40μm fine features,reduced by 87%compared to existing hard magnetic photosensitive resin,and exhibits significantly enhanced coercivity and remanence in comparison with existing soft magnetic photosensitive resins,showing by an increase of 24 times and 6 times,respectively.The reported NdFeB-Fe_(3)O_(4) magnetic photosensitive resin is anticipated to provide a new functional material for the design and manufacture of next-generation micro-robotics,electromagnetic sensor,and magneto-thermal devices.

Investigation on the Mechanical Properties and Shape Memory Effect of Landing Buffer Structure Based on NiTi Alloy Printing

With the deepening of human research on deep space exploration,our research on the soft landing methods of landers has gradually deepened.Adding a buffer and energy-absorbing structure to the leg structure of the lander has become an effective design solution.Based on the energy-absorbing structure of the leg of the interstellar lander,this paper studies the appearance characteristics of the predatory feet of the Odontodactylus scyllarus.The predatory feet of the Odontodactylus scyllarus can not only hit the prey highly when preying,but also can easily withstand the huge counter-impact force.The predatory feet structure of the Odontodactylus scyllarus,like a symmetrical cone,shows excellent rigidity and energy absorption capacity.Inspired by this discovery,we used SLM technology to design and manufacture two nickel-titanium samples,which respectively show high elasticity,shape memory,and get better energy absorption capacity.This research provides an effective way to design and manufacture high-mechanical energy-absorbing buffer structures using bionic 3D printing technology and nickel-titanium alloys.

3D printing critical materials for rechargeable batteries: from materials, design and optimization strategies to applications

Three-dimensional(3D)printing,an additive manufacturing technique,is widely employed for the fabrication of various electrochemical energy storage devices(EESDs),such as batteries and supercapacitors,ranging from nanoscale to macroscale.This technique offers excellent manufacturing flexibility,geometric designability,cost-effectiveness,and eco-friendliness.Recent studies have focused on the utilization of 3D-printed critical materials for EESDs,which have demonstrated remarkable electrochemical performances,including high energy densities and rate capabilities,attributed to improved ion/electron transport abilities and fast kinetics.However,there is a lack of comprehensive reviews summarizing and discussing the recent advancements in the structural design and application of 3D-printed critical materials for EESDs,particularly rechargeable batteries.In this review,we primarily concentrate on the current progress in 3D printing(3DP)critical materials for emerging batteries.We commence by outlining the key characteristics of major 3DP methods employed for fabricating EESDs,encompassing design principles,materials selection,and optimization strategies.Subsequently,we summarize the recent advancements in 3D-printed critical materials(anode,cathode,electrolyte,separator,and current collector)for secondary batteries,including conventional Li-ion(LIBs),Na-ion(SIBs),K-ion(KIBs)batteries,as well as Li/Na/K/Zn metal batteries,Zn-air batteries,and Ni–Fe batteries.Within these sections,we discuss the 3DP precursor,design principles of 3D structures,and working mechanisms of the electrodes.Finally,we address the major challenges and potential applications in the development of 3D-printed critical materials for rechargeable batteries.

3D bioprinting of complex biological structures with tunable elastic modulus and porosity using freeform reversible embedding of suspended hydrogels

Three-dimensional(3D)bioprinting has been used widely for the construction of hard tissues such as bone and cartilage.However,constructing soft tissues with complex structures remains a challenge.In this study,complex structures characterized by both tunable elastic modulus and porosity were printed using freeform reversible embedding of suspended hydrogels(FRESHs)printing methods.A mixture of alginate and gelatin was used as the main functional component of the bioink.Rheological analysis showed that this bioink possesses shear thinning and shear recovery properties,supporting both cryogenic and FRESH printing methods.Potential printing capabilities and limitations of cryogenic and FRESH printing were then analyzed by printability tests.A series of complex structures were printed by FRESH printing methods which could not be realized using conventional approaches.Mechanical tests and scanning electron microscopy analysis showed that the printed structure is of excellent flexibility and could be applied in various conditions by adjusting its mechanical modulus and porosity.L929 fibroblast cells maintained cell viability in cell-laden-printed structures,and the addition of collagen further improved the hydrogels’biocompatibility.Overall,all results provided useful insight into the building of human soft tissue organ blocks.

3D printing of functional bioengineered constructs for neural regeneration: a review

Three-dimensional(3D)printing technology has opened a new paradigm to controllably and reproducibly fabricate bioengineered neural constructs for potential applications in repairing injured nervous tissues or producing in vitro nervous tissue models.However,the complexity of nervous tissues poses great challenges to 3D-printed bioengineered analogues,which should possess diverse architectural/chemical/electrical functionalities to resemble the native growth microenvironments for functional neural regeneration.In this work,we provide a state-of-the-art review of the latest development of 3D printing for bioengineered neural constructs.Various 3D printing techniques for neural tissue-engineered scaffolds or living cell-laden constructs are summarized and compared in terms of their unique advantages.We highlight the advanced strategies by integrating topographical,biochemical and electroactive cues inside 3D-printed neural constructs to replicate in vivo-like microenvironment for functional neural regeneration.The typical applications of 3D-printed bioengineered constructs for in vivo repair of injured nervous tissues,bio-electronics interfacing with native nervous system,neural-on-chips as well as brain-like tissue models are demonstrated.The challenges and future outlook associated with 3D printing for functional neural constructs in various categories are discussed.

Anisotropic creep behavior of soft-hard interbedded rock masses based on 3D printing and digital imaging correlation technology

Three-dimensional(3D)printing technology is increasingly used in experimental research of geotechnical engineering.Compared to other materials,3D layer-by-layer printing specimens are extremely similar to the inherent properties of natural layered rock masses.In this paper,soft-hard interbedded rock masses with different dip angles were prepared based on 3D printing(3DP)sand core technology.Uniaxial compression creep tests were conducted to investigate its anisotropic creep behavior based on digital imaging correlation(DIC)technology.The results show that the anisotropic creep behavior of the 3DP soft-hard interbedded rock mass is mainly affected by the dip angles of the weak interlayer when the stress is at low levels.As the stress level increases,the effect of creep stress on its creep anisotropy increases significantly,and the dip angle is no longer the main factor.The minimum value of the long-term strength and creep failure strength always appears in the weak interlayer within 30°–60°,which explains why the failure of the layered rock mass is controlled by the weak interlayer and generally emerges at 45°.The tests results are verified by comparing with theoretical and other published studies.The feasibility of the 3DP soft-hard interbedded rock mass provides broad prospects and application values for 3DP technology in future experimental research.

Advances in 3D printing scaffolds for peripheral nerve and spinal cord injury repair

Because of the complex nerve anatomy and limited regeneration ability of natural tissue,the current treatment effect for long-distance peripheral nerve regeneration and spinal cord injury(SCI)repair is not satisfactory.As an alternative method,tissue engineering is a promising method to regenerate peripheral nerve and spinal cord,and can provide structures and functions similar to natural tissues through scaffold materials and seed cells.Recently,the rapid development of 3D printing technology enables researchers to create novel 3D constructs with sophisticated structures and diverse functions to achieve high bionics of structures and functions.In this review,we first outlined the anatomy of peripheral nerve and spinal cord,as well as the current treatment strategies for the peripheral nerve injury and SCI in clinical.After that,the design considerations of peripheral nerve and spinal cord tissue engineering were discussed,and various 3D printing technologies applicable to neural tissue engineering were elaborated,including inkjet,extrusion-based,stereolithography,projection-based,and emerging printing technologies.Finally,we focused on the application of 3D printing technology in peripheral nerve regeneration and spinal cord repair,as well as the challenges and prospects in this research field.