技术领域Technical Field
本发明属于3D打印技术领域，尤其涉及一种金属3D打印的支撑自动修复方法。The present invention belongs to the technical field of 3D printing, and in particular relates to a method for automatically repairing supports in metal 3D printing.
背景技术Background Art
激光选区熔化(SLM)成形技术，作为增材制造领域的核心工艺之一，在复杂结构零件制造中展现出巨大的潜力。然而，在实际应用中，零件的成形效果和打印质量与支撑结构的稳定性有直接关系。在SLM成形过程中，网格支撑作为基材与零件实体之间的桥梁，为零件的悬空部分提供必要的支撑，确保零件在成形过程中不会因为重力作用而发生坍塌或变形。其次支撑结构有助于成形过程中积累热量的扩散，防止因局部过热导致的热应力集中和零件开裂。但在许多项目中，SLM打印过程中局部支撑失败的现象时有发生。这主要源于材料性能、打印参数、设备精度等多方面因素。局部打印支撑失败不仅会影响零件后续成形，还可能导致整个零件的成形失败，从而增加制造成本和时间成本。针对这一问题，传统的处理方法是暂停打印，通过人工方式修补支撑结构，但这样的方法不仅耗费时间，降低了生产效率。Selective laser melting (SLM) forming technology, as one of the core processes in the field of additive manufacturing, has shown great potential in the manufacturing of complex structural parts. However, in practical applications, the forming effect and printing quality of parts are directly related to the stability of the support structure. In the SLM forming process, the grid support acts as a bridge between the substrate and the part entity, providing necessary support for the suspended part of the part to ensure that the part will not collapse or deform due to gravity during the forming process. Secondly, the support structure helps to diffuse the accumulated heat during the forming process and prevents thermal stress concentration and part cracking caused by local overheating. However, in many projects, local support failure occurs during SLM printing. This is mainly due to factors such as material properties, printing parameters, and equipment accuracy. The failure of local printing support will not only affect the subsequent forming of the part, but may also lead to the failure of the forming of the entire part, thereby increasing the manufacturing cost and time cost. To address this problem, the traditional method is to suspend printing and repair the support structure manually, but this method is not only time-consuming, but also reduces production efficiency.
发明内容Summary of the invention
本发明的目的在于提供一种金属3D打印的支撑自动修复方法，能够对打印区域进行检测识别，在支撑打印失败时，及时进行修复，提高生产效率，减少零件成型失败的风险。The purpose of the present invention is to provide a method for automatically repairing supports for metal 3D printing, which can detect and identify the printing area, and when support printing fails, repair it in time, improve production efficiency, and reduce the risk of part molding failure.
为了达到上述目的，本发明的技术方案为：一种金属3D打印的支撑自动修复方法，包括以下步骤：In order to achieve the above object, the technical solution of the present invention is: a method for automatically repairing supports for metal 3D printing, comprising the following steps:
在3D打印设备开始打印一层支撑前，图像采集单元会获取每层铺粉前的原始图像和每层铺粉后的铺粉图像并发送给图像分析单元；Before the 3D printing device starts printing a layer of support, the image acquisition unit will obtain the original image before each layer of powder and the powder image after each layer of powder and send them to the image analysis unit;
在3D打印设备开始打印一层支撑后，图像采集单元会获取每层激光扫描烧结后的烧结图像并发送给图像分析单元；After the 3D printing device starts printing a layer of support, the image acquisition unit acquires the sintering image of each layer after laser scanning sintering and sends it to the image analysis unit;
所述图像分析单元会先对铺粉后的铺粉图像的灰度与每层铺粉前的原始图像的灰度值进行对比分析以及对铺粉后的铺粉图像的灰度值进行分析，判断铺粉是否均匀或是否有位置未铺粉；再对激光扫描烧结后的烧结图像和当前层理论烧结图像的灰度值进行对比，判断是否存在打印失败的问题；所述图像分析单元将分析结果发送给控制判定单元；The image analysis unit will first compare and analyze the grayscale of the powder-laying image after powder laying with the grayscale value of the original image before each layer of powder laying, and analyze the grayscale value of the powder-laying image after powder laying to determine whether the powder is laid evenly or whether there are any positions without powder laying; then compare the grayscale value of the sintering image after laser scanning sintering with the grayscale value of the theoretical sintering image of the current layer to determine whether there is a printing failure problem; the image analysis unit sends the analysis result to the control judgment unit;
所述控制判定单元对分析结果进行判定，若判定支撑打印状态正常时，继续下一层的打印；若判定支撑打印失败时，控制判定单元会启动轮廓提取单元从烧结图像中提取失败区域的轮廓并将提取的轮廓发送给支撑修复单元；The control and determination unit determines the analysis result. If it is determined that the support printing state is normal, the printing of the next layer will continue; if it is determined that the support printing fails, the control and determination unit will start the contour extraction unit to extract the contour of the failed area from the sintered image and send the extracted contour to the support repair unit;
所述支撑修复单元根据轮廓提取单元提取的轮廓生成修复路径；并根据修复路径进行修复打印。The support repair unit generates a repair path according to the contour extracted by the contour extraction unit, and performs repair printing according to the repair path.
进一步，若铺粉后的铺粉图像的打印区域存在与铺粉前的原始图像相同灰度值的区域，且相同灰度值的区域的灰度值与未打印区域的灰度值不同，则说明存在有位置未铺粉的情况；若铺粉后的铺粉图像的最大灰度值和最小灰度值之间的差额大于阈值，则说明存在铺粉不均匀的问题。Furthermore, if there is an area in the printed area of the powder-laying image after powdering with the same grayscale value as that of the original image before powdering, and the grayscale value of the area with the same grayscale value is different from the grayscale value of the unprinted area, it means that there is a position where powder is not applied; if the difference between the maximum grayscale value and the minimum grayscale value of the powder-laying image after powdering is greater than the threshold, it means that there is a problem of uneven powdering.
进一步，若激光扫描烧结后的烧结图像和当前层理论烧结图像的灰度值不一致时，说明该区域存在打印失败的问题。Furthermore, if the grayscale value of the sintered image after laser scanning sintering is inconsistent with the grayscale value of the theoretical sintered image of the current layer, it indicates that there is a printing failure problem in this area.
进一步，若判定支撑打印失败时，控制判定单元还会启动扫描单元对当前打印图层进行扫描，并将扫描信息上传至控制判定单元；Furthermore, if it is determined that the support printing fails, the control determination unit will also start the scanning unit to scan the current printing layer and upload the scanning information to the control determination unit;
若图像分析单元分析出当前层的铺粉图像的最大灰度值和最小灰度值之间的差额大于阈值且控制判定单元从扫描信息判断出存在翘曲的情况，则3D打印平台下降一个层厚，扫描单元再次扫描当前打印图层并将扫描信息发送给控制判定单元，控制判定单元对扫描图像平面高度进行判定，若平面高度与当前层层高一致，则启动支撑修复单元进行修复；若平面高度仍高于当前层层高，则继续下降一个层厚并重复上述步骤，直至平面高度与当前层层高一致。If the image analysis unit analyzes that the difference between the maximum grayscale value and the minimum grayscale value of the powder image of the current layer is greater than the threshold and the control judgment unit determines from the scanning information that warping exists, the 3D printing platform drops one layer thickness, the scanning unit scans the current printing layer again and sends the scanning information to the control judgment unit, and the control judgment unit determines the plane height of the scanned image. If the plane height is consistent with the current layer height, the support repair unit is started to repair it; if the plane height is still higher than the current layer height, it continues to drop one layer thickness and repeat the above steps until the plane height is consistent with the current layer height.
进一步，所述支撑修复单元根据轮廓提取单元提取的轮廓计算出轮廓的边界，并将其转化为若干连续的点或线段，由这些点和线段组成新的支撑结构与几何形状，再覆盖打印失败区域的边界，从而生成修复路径，并按照修复路径进行打印修复。Furthermore, the support repair unit calculates the boundary of the contour based on the contour extracted by the contour extraction unit, and converts it into a number of continuous points or line segments, which form a new support structure and geometric shape, and then cover the boundary of the printing failure area, thereby generating a repair path, and performing printing repair according to the repair path.
进一步，修复路径设定好之后，扫描单元确保平台高度后，3D打印设备首先需要重新铺上一层粉末，然后激光会对修复路径中的区域重新进行打印，修复打印失败区域。Furthermore, after the repair path is set and the scanning unit ensures the platform height, the 3D printing device first needs to reapply a layer of powder, and then the laser will reprint the area in the repair path to repair the failed printing area.
进一步，若控制判定单元连续两次判定存在有位置未铺粉的情况，则控制判定单元发送告警信号给所述3D打印设备，并暂时停止打印。Furthermore, if the control determination unit determines twice in succession that there is a position where powder is not applied, the control determination unit sends an alarm signal to the 3D printing device and temporarily stops printing.
本技术方案的有益效果在于：本技术方案能够及时对打印的每一层进行检测，在检测到支撑打印失败后，及时进行修复，不需要人工修补，提高生产效率，减少零件成型失败的风险。The beneficial effect of this technical solution is that it can detect each printed layer in time, and after detecting support printing failure, it can be repaired in time without manual repair, thereby improving production efficiency and reducing the risk of part molding failure.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
图1为本发明一种金属3D打印的支撑自动修复方法的流程图。FIG1 is a flow chart of a method for automatically repairing supports for metal 3D printing according to the present invention.
具体实施方式DETAILED DESCRIPTION
下面通过具体实施方式进一步详细说明：The following is further described in detail through specific implementation methods:
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.
实施例基本如附图1所示：一种金属3D打印的支撑自动修复方法，包括以下步骤：The embodiment is basically as shown in Figure 1: a method for automatically repairing supports for metal 3D printing, comprising the following steps:
步骤S1:在3D打印设备开始打印一层支撑前，图像采集单元会获取每层铺粉前的原始图像和每层铺粉后的铺粉图像并发送给图像分析单元；图像采集单元可以采用相机，图像分析单元可以采用计算机；Step S1: before the 3D printing device starts printing a layer of support, the image acquisition unit will obtain the original image before each layer of powder and the image after each layer of powder and send them to the image analysis unit; the image acquisition unit can use a camera, and the image analysis unit can use a computer;
步骤S2:在3D打印设备开始打印一层支撑后，图像采集单元会获取每层激光扫描烧结后的烧结图像并发送给图像分析单元；Step S2: After the 3D printing device starts printing a layer of support, the image acquisition unit acquires the sintering image of each layer after laser scanning sintering and sends it to the image analysis unit;
步骤S3:图像分析单元会先对铺粉后的铺粉图像的灰度与每层铺粉前的原始图像的灰度值进行对比分析以及对铺粉后的铺粉图像的灰度值进行分析，判断铺粉是否均匀或是否有位置未铺粉；若铺粉后的铺粉图像的打印区域存在与铺粉前的原始图像相同灰度值的区域，且相同灰度值的区域的灰度值与未打印区域的灰度值不同，则说明存在有位置未铺粉的情况，也即是打印完成的区域存在未铺粉的情况，打印完成的区域由于未铺粉，会与铺粉位置的灰度值不同；若铺粉后的铺粉图像的最大灰度值和最小灰度值之间的差额大于阈值，则说明存在铺粉不均匀的问题。再对激光扫描烧结后的烧结图像和当前层理论烧结图像的灰度值进行对比，判断是否存在打印失败的问题；若激光扫描烧结后的烧结图像和当前层理论烧结图像的灰度值不一致时，说明该区域存在打印失败的问题。此处原理在于，因为打印失败区域的支撑网格不规范，导致图像灰度值不一致，打印失败区域和正常支撑区域的区别。(本专利中的灰度，它指的是图像的灰度级别，在数字图像中，灰度级别表示图像中每个像素的亮度，通常在0黑色到255白色之间的范围内。因此，本文中的增材制造设备内置相机捕捉的图像均为黑白两色，没有彩色信息)。图像分析单元将分析结果发送给控制判定单元；Step S3: The image analysis unit will first compare and analyze the grayscale of the powder-laying image after powder-laying with the grayscale value of the original image before each layer of powder-laying, and analyze the grayscale value of the powder-laying image after powder-laying to determine whether the powder-laying is uniform or whether there are positions where powder is not laid; if the printed area of the powder-laying image after powder-laying has an area with the same grayscale value as the original image before powder-laying, and the grayscale value of the area with the same grayscale value is different from the grayscale value of the unprinted area, it means that there is a position where powder is not laid, that is, there is a situation where powder is not laid in the printed area, and the printed area will have a different grayscale value from the powder-laying position due to the lack of powder; if the difference between the maximum grayscale value and the minimum grayscale value of the powder-laying image after powder-laying is greater than the threshold, it means that there is a problem of uneven powder-laying. Then compare the grayscale values of the sintered image after laser scanning sintering and the theoretical sintered image of the current layer to determine whether there is a problem of printing failure; if the grayscale values of the sintered image after laser scanning sintering and the theoretical sintered image of the current layer are inconsistent, it means that there is a problem of printing failure in this area. The principle here is that because the support grid of the failed printing area is not standardized, the grayscale value of the image is inconsistent, and the difference between the failed printing area and the normal support area. (The grayscale in this patent refers to the grayscale level of the image. In a digital image, the grayscale level represents the brightness of each pixel in the image, usually in the range of 0 black to 255 white. Therefore, the images captured by the built-in camera of the additive manufacturing device in this article are all black and white, without color information). The image analysis unit sends the analysis results to the control judgment unit;
步骤S4:控制判定单元对分析结果进行判定，若判定支撑打印状态正常时，继续下一层的打印；若判定支撑打印失败时，控制判定单元会启动轮廓提取单元和扫描单元，轮廓提取单元从烧结图像中提取失败区域的轮廓并将提取的轮廓发送给支撑修复单元；扫描单元会对当前打印图层进行扫描，并将扫描信息上传至控制判定单元。若控制判定单元连续两次判定存在有位置未铺粉的情况，则控制判定单元发送告警信号给3D打印设备，并暂时停止打印。Step S4: The control and determination unit determines the analysis results. If it is determined that the support printing state is normal, the next layer of printing will continue; if it is determined that the support printing fails, the control and determination unit will start the contour extraction unit and the scanning unit. The contour extraction unit extracts the contour of the failed area from the sintered image and sends the extracted contour to the support repair unit; the scanning unit scans the current printing layer and uploads the scanning information to the control and determination unit. If the control and determination unit determines twice in a row that there is a position where powder is not applied, the control and determination unit sends an alarm signal to the 3D printing device and temporarily stops printing.
步骤S5:若图像分析单元分析出当前层的铺粉图像的最大灰度值和最小灰度值之间的差额大于阈值且控制判定单元从扫描信息判断出存在翘曲的情况，则3D打印平台下降一个层厚，扫描单元再次扫描当前打印图层并将扫描信息发送给控制判定单元，控制判定单元对扫描图像平面高度进行判定，若平面高度与当前层层高一致，则启动支撑修复单元进行修复；若平面高度仍高于当前层层高，则继续下降一个层厚并重复上述步骤，直至平面高度与当前层层高一致(若无法达到一致，则稍低于当前层层高也可以)。支撑修复单元根据轮廓提取单元提取的轮廓生成修复路径；并根据修复路径进行修复打印，具体地支撑修复单元根据轮廓提取单元提取的轮廓计算出轮廓的边界，并将其转化为若干连续的点或线段，由这些点和线段组成新的支撑结构与几何形状，再覆盖打印失败区域的边界，从而生成修复路径。Step S5: If the image analysis unit analyzes that the difference between the maximum grayscale value and the minimum grayscale value of the powder image of the current layer is greater than the threshold value and the control determination unit determines from the scanning information that there is warping, the 3D printing platform drops one layer thickness, the scanning unit scans the current printing layer again and sends the scanning information to the control determination unit, the control determination unit determines the plane height of the scanned image, if the plane height is consistent with the current layer height, the support repair unit is started to repair; if the plane height is still higher than the current layer height, it continues to drop one layer thickness and repeat the above steps until the plane height is consistent with the current layer height (if it cannot be consistent, it is also OK to be slightly lower than the current layer height). The support repair unit generates a repair path according to the contour extracted by the contour extraction unit; and performs repair printing according to the repair path. Specifically, the support repair unit calculates the boundary of the contour according to the contour extracted by the contour extraction unit, and converts it into a number of continuous points or line segments, which are composed of these points and line segments to form a new support structure and geometric shape, and then cover the boundary of the printing failure area, thereby generating a repair path.
根据不同的材料特性，会预先设置不同的打印参数，具体为向量间距、向量功率、扫描速度。向量间距决定了修复路径上相邻点之间的距离，向量功率影响了修复路径的密度和填充程度，扫描速度则影响了打印过程中的速度和精度。Different printing parameters will be pre-set according to different material properties, specifically vector spacing, vector power, and scanning speed. Vector spacing determines the distance between adjacent points on the repair path, vector power affects the density and filling degree of the repair path, and scanning speed affects the speed and accuracy of the printing process.
步骤S6:修复路径设定好之后，扫描单元确保平台高度后，3D打印设备首先需要重新铺上一层粉末，然后激光会对修复路径中的区域重新进行打印，修复打印失败区域。Step S6: After the repair path is set and the scanning unit ensures the platform height, the 3D printing device first needs to re-apply a layer of powder, and then the laser will re-print the area in the repair path to repair the failed printing area.
本技术方案能够及时对打印的每一层进行检测，在检测到支撑打印失败后，及时进行修复，不需要人工修补，提高生产效率，减少零件成型失败的风险。This technical solution can detect each printed layer in time, and after detecting support printing failure, it can be repaired in time without the need for manual repair, thereby improving production efficiency and reducing the risk of part molding failure.
需要说明的是，在本文中，诸如第一和第二等之类的关系术语仅仅用来将一个实体或者操作与另一个实体或操作区分开来，而不一定要求或者暗示这些实体或操作之间存在任何这种实际的关系或者顺序。而且，术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含，从而使得包括一系列要素的过程、方法、物品或者设备不仅包括那些要素，而且还包括没有明确列出的其他要素，或者是还包括为这种过程、方法、物品或者设备所固有的要素。It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.
以上所述的仅是本发明的实施例，方案中公知的具体结构及特性等常识在此未作过多描述，所属领域普通技术人员知晓申请日或者优先权日之前发明所属技术领域所有的普通技术知识，能够获知该领域中所有的现有技术，并且具有应用该日期之前常规实验手段的能力，所属领域普通技术人员可以在本申请给出的启示下，结合自身能力完善并实施本方案，一些典型的公知结构或者公知方法不应当成为所属领域普通技术人员实施本申请的障碍。应当指出，对于本领域的技术人员来说，在不脱离本发明结构的前提下，还可以作出若干变形和改进，这些也应该视为本发明的保护范围，这些都不会影响本发明实施的效果和专利的实用性。本申请要求的保护范围应当以其权利要求的内容为准，说明书中的具体实施方式等记载可以用于解释权利要求的内容。The above is only an embodiment of the present invention. The common sense such as the known specific structure and characteristics in the scheme is not described in detail here. The ordinary technicians in the relevant field know all the common technical knowledge in the technical field of the invention before the application date or priority date, can obtain all the existing technologies in the field, and have the ability to apply the conventional experimental means before that date. The ordinary technicians in the relevant field can improve and implement this scheme in combination with their own abilities under the enlightenment given by this application. Some typical known structures or known methods should not become obstacles for ordinary technicians in the relevant field to implement this application. It should be pointed out that for those skilled in the art, without departing from the structure of the present invention, several deformations and improvements can be made, which should also be regarded as the protection scope of the present invention, which will not affect the effect of the implementation of the present invention and the practicality of the patent. The protection scope required by this application shall be based on the content of its claims, and the specific implementation methods and other records in the specification can be used to interpret the content of the claims.
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202410686390.6ACN118595459A (en) | 2024-05-30 | 2024-05-30 | A method for automatically repairing supports for metal 3D printing |
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202410686390.6ACN118595459A (en) | 2024-05-30 | 2024-05-30 | A method for automatically repairing supports for metal 3D printing |
| Publication Number | Publication Date |
|---|---|
| CN118595459Atrue CN118595459A (en) | 2024-09-06 |
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202410686390.6APendingCN118595459A (en) | 2024-05-30 | 2024-05-30 | A method for automatically repairing supports for metal 3D printing |
| Country | Link |
|---|---|
| CN (1) | CN118595459A (en) |
| Publication | Publication Date | Title |
|---|---|---|
| CN106312062B (en) | A kind of method and increasing material manufacturing equipment for examining powdering quality | |
| CN106881462B (en) | A kind of on-line checking and optimization system for selective laser fusing forming defects | |
| JP6533789B2 (en) | Method of monitoring the energy density of a laser beam by image analysis, and corresponding apparatus | |
| CN101678613B (en) | Method for producing a three-dimensional object by means of laser sintering | |
| CN106990114A (en) | Increasing material manufacturing defect inspection method and increasing material manufacturing device | |
| CN111168064B (en) | A method for automatic repair of supports based on additive manufacturing | |
| US20210101332A1 (en) | Manufacturing system of additive manufacturing body and manufacturing method of additive manufacturing body | |
| JP2016142601A (en) | Construction quality evaluation program, construction quality evaluation method, and construction quality evaluation device | |
| CN116117169B (en) | A SLM process defect detection method and device | |
| JP2024109915A (en) | Detecting resin adhesion defects | |
| JP2012002531A (en) | Crack detection method | |
| CN111735850A (en) | Scanning circuit board solder joint virtual welding automatic detection system and detection method | |
| CN113068326B (en) | A kind of welding quality processing method and device, circuit board | |
| CN113222937A (en) | Detection method and detection device for appearance peripheral surface defects of nuclear fuel pellet | |
| CN113195130A (en) | Method for operating a production system and production system for additive production of components from powdered material | |
| CN118595459A (en) | A method for automatically repairing supports for metal 3D printing | |
| CN118905468A (en) | Intelligent laser cutting regulation and control method and system | |
| CN117351005A (en) | Method and system for detecting coating defects of carbon-coated foil | |
| CN108305285A (en) | A kind of honeycomb sandwich structures disengagement area accounting measurement method | |
| CN111223098B (en) | Trolley grate inclination angle detection method and system of sintering machine | |
| CN110548876B (en) | Powder-laying type remanufacturing device and method | |
| CN108509665B (en) | Modeling method of light intensity data field of molten pool detected by photodiode | |
| US20250028307A1 (en) | Computer-implemented method of providing structured data of an additive manufacturing process | |
| CN105154869B (en) | A kind of laser melting coating scanning pattern acquisition methods repaired for uiform section solid object surface | |
| CN109940275A (en) | The laser blasting method of coin die is commonly commemorated in the sustainable punching press of high frequency time |
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| TA01 | Transfer of patent application right | ||
| TA01 | Transfer of patent application right | Effective date of registration:20241128 Address after:401336 No.6, electromechanical Branch Road, Nan'an District, Chongqing Applicant after:CHONGQING ELECTRICAL AND MECHANICAL INTELLIGENT MANUFACTURING CO.,LTD. Country or region after:China Address before:401336 floor 2, building 1, No. 8, electromechanical 1st branch road, Nan'an District, Chongqing Applicant before:Chongqing electromechanical Additive Manufacturing Co.,Ltd. Country or region before:China |