Method for manufacturing metal parts and molds and micro-roller used therefor

摘要

A method for manufacturing parts and molds by: 1) slicing a three-dimensional CAD model of a part or mold; 2) planning a modeling path according to slicing data of the three-dimensional CAD model, whereby generating numerical control codes for modeling processing; and 3) performing fused deposition modeling of powders or wire material of metal, intermetallic compounds, ceramic and composite functional gradient materials by layer using a welding gun on a substrate layer via a numerical control gas shielded welding beam or laser beam according to a track specified by the numerical control code for each layer. A micro-roller or a micro-extrusion unit is installed at a contact area between melted and softened areas. The micro-roller or the micro-extrusion unit synchronously moves along with fused deposition area, which results in compressing and processing of the fused deposition area during the fused deposition modeling.

主权项

1. A method for manufacturing a part comprising a plurality of layers, the method comprising:
a) slicing a three-dimensional CAD model of the part into a plurality of slices to attain geometric data of said slices; b) generating modeling paths for said slices according to said geometric data, and generating numerical control codes for said modeling paths; c) depositing material via fused deposition modeling on a substrate layer, by driving a welding gun emitting a numerical control gas shielded welding beam or laser beam along one of said modeling paths specified by one of said numerical control codes, to attain fused deposited material having two side surfaces, a bottom surface, and a top surface, wherein said bottom surface contacts with said substrate layer, said top surface is opposite to said bottom surface, said two side surfaces extend between said bottom surface and said top surface, and said two side surfaces are opposite to each other; and d) applying extrusion forces on said fused deposited material by using a micro-roller or a micro-extrusion unit to cause a plastic deformation in said fused deposited material;wherein:
said micro-roller or said micro-extrusion unit synchronously moves along with said welding gun, whereby the step of depositing material and the step of applying extrusion forces on said fused deposited material are substantially synchronously conducted; performing the substantially synchronous steps of depositing material and applying extrusion forces on said fused deposited material, until requirements for dimensions and surface quality of the part are met, whereby forming one of the plurality of layers; and the step of applying extrusion forces on said fused deposited material comprises applying extrusion forces on said two side surfaces and said top surface.