پرینتر سه بعدی در تولید قطعه با کمک قالب های سیلیکونی
ساخت جیگ و فیکسچر با چاپگر سه بعدی
دسامبر 27, 2016تکنولوژی SLA و Polyjet در پرینت سه بعدی
دسامبر 27, 2016استفاده از پرینتر سه بعدی در تولید قطعه با کمک قالب های سیلیکونی
در صنایع مختلف گاهی ساخت تعداد محدودی از یک قطعه لازم می گردد. در این شرایط ساخت قالبهای متداول بسیار هزینه بر و زمان بر می باشد. روش متداول برای ساخت اینگونه قطعات استفاده از قالب سیلیکونی می باشد.
با هر قالب سیلیکونی بطور متوسط حدود بیست قطعه قابل ساخت می باشد. پس از تولید تعدادی قطعه (بسته به نوع قطعه و … ) قالب مستهلک شده و کیفیت قطعات تولید شده توسط آن پایین می آید و برای تولید قطعات بیشتر باید قالب جدیدی ساخته شود.
در روش تولید قطعه به کمک قالب های سیلیکونی ، نیاز به یک قطعه اصلی یا مستر میباشد تا ابتدا با سیلیکون از آن قالبگیری شود. این قطعه اصلی یا اولیه را می توان با استفاده از دستگاه های چاپگر سه بعدی تولید نمود. پرینترهای سه بعدی این امکان را در اختیار افراد قرار می دهند تا هر قطعه با هر شکل و پیچیدگی را در زمان کوتاهی بسازند. اکثر چاپگرهای سه بعدیاز مواد پلاستیکی استفاده می کنند. قطعه ساخته شده به روش پرینت سه بعدی دارای استحکام لازم برای قالبگیری می باشد.
قطعات ساخته شده با چاپگر سه بعدی معمولا” دارای کیفیت سطح مناسب نمی باشند. لذا می بایستی عملیات پولیشکاری روی قطعه نمونه سازی شده انجام گردد و این امر زمانی با کیفیت بهتر انجام می شود که جنس قطعه پرینت سه بعدی شده از پلاستیک ABS باشد .
برای قالبگیری ابتدا باید قطعه ساخته شده با پرینتر سه بعدی روی قطعه هایی از چوب یا پلاستیک محکم گردد تا از جابجایی آن هنگام ریختن سیلیکون جلوگیری شود. برای این کار می توان از چسب یا گل مخصوص مدلسازی استفاده کرد.
اکنون باید جعبه قالب را ساخت. برای این کار باید از موادی مثل تخته چوب یا ورق پلاستیک با سطح صاف و بدون خلل و فرج استفاده کرد.
جعبه مورد نظر باید حدود بیست و پنج تا پنجاه درصد بزرگتر از قطعه ساخته شده با پرینتر سه بعدی باشد. می توان جعبه را از تخته چوب یا ورق پلاستیک ساخت و با چسب یا گل مدلسازی آب بند نمود تا سیلیکون مایع از آن بیرون نریزد.
در مرحله بعد باید سیلیکون مورد نیاز آماده گردد. مواد مورد استفاده در قالب سیلیکونی از رزینهای دو جزئی می باشند که یکی ماده اصلی و دیگری سخت کننده است. لذا با توجه به حجم قطعه، میزان مواد مورد نیاز محاسبه شده و پس از این که خوب با هم مخلوط شدند به آرامی داخل قالب ریخته میشوند. سپس اجازه دهید تا سیلیکون به آرامی اطراف قطعه را پر کند. سیلیکون باید روی سطح قطعه را بپوشاند. زمان مورد نیاز برای سفت شدن سیلیکون بین 8 تا 18ساعت می باشد که بسته به میزان دما و رطوبت محیط کم یا زیاد می شود.
پس از سفت شدن سیلیکون، قالب را بریده و سپس به آرامی قطعه ساخته شده با چاپگر سه بعدی را از داخل سیلیکون سفت شده خارج میکنیم. اکنون قالب برای ساخت قطعات جدید آماده است.
در مرحله بعد مواد اصلی مورد نیاز برای ساخت قطعه را با هم مخلوط و آماده می کنیم. با توجه به حجم قطعه، میزان رزین مورد نیاز را برآورد کرده و با هم خوب مخلوط می کنیم.
قبل از ریختن رزین به داخل قالب بهتر است قالب را کمی پیش گرم کنیم. پیش گرم کردن قالب این مزیت را دارد که رزین ریخته شده به داخل قالب سریعتر و بهتر سفت می گردد. این موضوع به خصوص برای قطعات کوچک یا با دیواره نازک بسیار مفید میباشد.
استفاده از ماده جدا کننده برای افزایش عمر قالب توصیه میگردد. ماده جدا کننده روی سیلیکون مالیده شده و باعث میشود قطعه به سیلیکون نچسبد.
رزین را به آرامی داخل قالب میریزیم و اجازه میدهیم تمام گوشه ها و جزئیات قطعه را پر کند. همچنین باید اجازه دهیم تا هوا از داخل قالب خارج گردد. در صورت لزوم می توان قالب را با دست فشار داد تا رزین در تمام کنجها نفوذ کند.
رزین ریخته شده در قالب یه تدریج از حالت مایع به جامد تغییر حالت میدهد و با تغییر رنگ آن قابل مشاهده است. زمان سخت شدن قطعه بسته به بزرگی یا کوچکی آن، پیش گرم کردن قالب و یا استفاده از مواد تسریع کننده واکنش سخت شدن رزین دارد .
بطور کلی قطعات بزرگتر زودتر سفت شده و فرم می گیرند و قطعات کوچک و یا نازک زمان بیشتری برای سخت شدن نیاز دارند. پس از سخت شدن قطعه، آن را به آرامی از قالب سیلیکونی خارج نمایید.
معمولا در هنگام سخت شدن رزین گازی ایجاد میگردد که به صورت حبابهای ریز روی سطح قطعه دیده میشوند. برای این که تنش سطحی قطعه از بین برود و همچنین حبابهای سطحی قطعه کم شده یا از بین بروند بهتر است کمی پودر تالک یا پودر بچه روی سطح قالب سیلیکونی ریخته شود.
از آنجاییکه رزینهای مورد استفاده در قالب سیلیکونی به رطوبت حساس هستند بهتر است پس از استفاده درب ظروف را بسته و در جای خشک و خنک نگهداری گردند.
از راهنمایی های شرکت پیشگام فناوران آرکا جهت انواع نمونه سازی سریع بهره مند شوید.
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