基于气/电/热协同驱动喷射微3D打印低成本制造高精度共形薄膜

doi:10.3901/JME.260087

摘要/Abstract

摘要： 高精度曲面共形薄膜/涂层是三维曲面共形电子、结构健康监测、智能蒙皮、共形传感器等产品的重要组成部分，广泛应用于航空航天、国防军工、智能电子等领域。但高效、低成本、常温常压制造高精度共形薄膜仍是当前亟待突破的难题。提出一种三轴联动的气/电/热协同驱动喷射微3D打印高精度共形薄膜新方法：通过气压驱动材料进入喷头，压电撞针协同喷头加热实现高黏度材料微滴稳定喷射，基底加热调控微滴在曲面的沉积固化行为，最终实现高黏度材料高精度共形薄膜制备；以工业界广泛应用的聚酰亚胺(PI)材料为例，探究了适合所提方法打印材料的流变行为和黏度特性；通过实验揭示了主要工艺参数对共形薄膜制备稳定性、厚度均匀性以及表面质量的影响及其规律。结合优化的工艺参数，在半圆柱玻璃基底上制得平均厚度约22 μm，偏差小于2 μm的高精度PI曲面共形薄膜；该方法适合不同黏度材料(PI、氧化锆陶瓷、PDMS等)，可在多种基底材料(玻璃、树脂、金属等)、多种复杂曲面基底形状(如球面、阶梯面、波浪面等)上制备高精度共形薄膜，具有良好普适性。制备的曲面薄膜加热器在14 V电压下最高温度达144.3 ℃，加热区域温度偏差<2%，显示出高度均匀的加热效果。提出方法为常温常压条件下高效低成本制造高精度共形薄膜/涂层提供了一种具有工业化应用前景的全新解决方案。

关键词: 气/电/热协同驱动喷射微3D打印, 共形薄膜, 微滴, 原位固化, 高黏度材料喷射

Abstract: High-precision curved conformal films/coatings are an important part of 3D curved conformal electronics, structural health monitoring, intelligent skins, conformal sensors and other products, which have extensive applications in aerospace, national defense and military industries, and intelligent electronics field. However, the efficient, low-cost, normal temperature/pressure manufacturing of high-precision conformal films is a major problem in current research. A new method for manufacturing high-precision conformal films is proposed by three-axis linked pneumatic/electricity/heat synergistically driven jetting micro-3D printing: through the pneumatic pressure to drive material into the nozzle, piezoelectric impact needle synergistic nozzle heating to achieve stable jetting of high viscosity material microdroplets, substrate heating regulates the deposition and curing behavior of microdroplets on curved surfaces, and ultimately realizes the preparation of high-precision conformal films using high-viscosity materials; Taking the industrially widespread polyimide (PI) material as a case study, we investigated the rheological behavior and viscosity characteristics of the material suitable for printing via the proposed method; Through experiments, the influences of key process parameters on stability of conformal film preparation, thickness uniformity, and surface quality are revealed;Combined with the optimized process parameters, high-precision PI conformal films with an average thickness of 22 μm and thickness deviation <2 μm were successfully fabricated on semi-cylindrical glass substrates, This method is suitable for materials with different viscosities (such as PI, zirconia ceramics, PDMS, etc.), and can fabricate high-precision conformal films on various substrate materials (glass, resin, metal, etc.) and on multiple complex curved substrate surfaces (e.g., spherical surfaces, stepped surfaces, wavy surfaces, etc.), exhibiting good universality. The prepared curved-film heater achieves a maximum temperature of 144.3 ℃ at 14 V, with a temperature deviation of <2% in the heating area, showing a highly uniform heating effect. This proposed method provides a new solution with industrialized application prospects for efficient and low-cost fabrication of high-precision conformal films/coatings under normal temperature and pressure conditions.

Key words: pneumatic/electrical/thermal synergistically driven jetting micro-3D printing, conformal films, microdroplet, in-situ curing, high-viscosity material jetting

中图分类号:

TB383

王勇强, 张厚超, 黄君杰, 李红珂, 朱晓阳, 杨建军, 兰红波. 基于气/电/热协同驱动喷射微3D打印低成本制造高精度共形薄膜[J]. 机械工程学报, 2026, 62(3): 298-310.

WANG Yongqiang, ZHANG Houchao, HUANG Junjie, LI Hongke, ZHU Xiaoyang, YANG Jianjun, LAN Hongbo. Low-cost Fabrication of High-precision Conformal Films Based on Pneumatic/Electrical/Thermal Synergistically Driven Jetting Micro-3D Printing[J]. Journal of Mechanical Engineering, 2026, 62(3): 298-310.

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