METHOD OF PRODUCING ARTICLE ON NON-DETACHABLE POLYMER SUBSTRATE BY FDM PRINTING Russian patent published in 2024 - IPC B29C64/118 B33Y10/00 B29C65/02 B29C51/14 

FIELD: various technological processes.

SUBSTANCE: group of inventions relates to additive manufacturing technologies, in particular to versions of production of articles by layer-by-layer fusion of thermoplastic materials on a non-detachable substrate, which is a structural part of finished articles. One of the versions relates to a method in which 3D model of the required part is created, facets of the model are determined, the initial model is refined, series of 2D cuts – 3D printing layers is obtained, compositions of filament and non-detachable polymer substrate are selected. Filament material used is an organic polymer. If necessary, filament filler is selected. Material of the non-detachable polymer substrate is then selected to be an organic polymer such that it has affinity for the filament material, wherein in most cases, the material of the non-detachable polymer substrate is selected from the material of the filament. If necessary, for films or sheets of non-detachable polymer substrate, a filler is selected at its concentration in the organic polymer of up to 60 wt.% depending on the type of organic polymer and filler; wherein non-detachable polymer substrate is included in the article and is its structural part. Further determining the dimensions of the non-detachable polymer substrate, its thickness, as well as the angle of rotation, if the non-detachable polymer substrate is reinforced with unidirectional continuous glass or carbon fibre or is a thermoplastic laminate with a certain reinforcement pattern, and after cutting to preset dimensions, the non-detachable polymer substrate, which, as a rule, has dimensions less than the dimensions of the table, is fixed on the table either by means of an adhesive double-sided tape which withstands temperature of the table without considerable deterioration of its properties, or by means of soluble glue, or mechanical clamps. After that, layers are printed line-by-line by fused filaments – FDM-printing at nozzle temperatures of 150–450 °C depending on the selected printing material and at the temperature of the table, which provides strong fusion of the first layer of the article to the substrate, until the printed article is completely formed. Further, the printed article is subjected to mechanical treatment, including cutting of the non-detachable polymer substrate to the required dimensions and removal of supports, and, if necessary, final abrasive treatment of the article surface is carried out.

EFFECT: wider range of materials used as a substrate, use of substrates of different sizes, including those larger than the size of the printing table, use of polymer sheets as a structural part of the printed article, id est without separating the substrate from the article, which in turn enables to achieve a more efficient arrangement of the printed article on the table and simplification of the technological process, possibility of using thermoforming to obtain closed polymer printed articles tightly connected to a substrate, which widens the range of manufactured articles and possibility of making gradient materials.

6 cl, 3 dwg, 5 ex