Manufacturing method for lightweight parts combining porous metal substrate and functional resin
View Patent ↗A method for manufacturing a lightweight part including a porous metal matrix having a functional resin bonded thereto is disclosed. The method includes a porous metal matrix preparation step of preparing a porous metal matrix; a base layer deposition step in which while a nozzle of a FDM (Fused Deposition Modeling) 3D printer moves along a first predetermined movement coordinate path, the nozzle heats and extrudes a resin filament toward a surface of the porous metal matrix to infiltrate a molten resin into closed pores or depressions in the surface of the porous metal matrix, thereby forming a base layer bonded to the surface of the porous metal matrix; and a build layer deposition step in which while the nozzle moves along the first set movement coordinate path or a predetermined second set movement coordinate path different from the first set movement coordinate path, the nozzle heats and extrudes the resin filament toward the base layer such that one or more flat or curved build layers are deposited on the base layer, wherein the resin filament is made of a functional resin material.
1 . A method for manufacturing a part, the method comprising:
a porous metal matrix preparation step of preparing a porous metal matrix, wherein the metal matrix comprises a metal having closed pores defined therein;
a base layer deposition step in which while a nozzle of a fused deposition modeling 3D printer moves along a first predetermined movement coordinate path, the nozzle heats and extrudes a resin filament in linear layers toward a surface of the porous metal matrix to infiltrate a molten resin into pores or depressions in the surface of the porous metal matrix, thereby forming a base layer bonded to the surface of the porous metal matrix, wherein some of the linear layers constituting the base layer penetrate into the pores or depressions in the surface of the porous metal matrix and then harden, thereby generating a bonding force between the base layer and the porous metal matrix; and
a build layer deposition step in which while the nozzle moves along the first set movement coordinate path or a predetermined second set movement coordinate path different from the first set movement coordinate path, the nozzle heats and extrudes the resin filament toward the base layer such that one or more flat or curved build layers are deposited on the base layer,
wherein the resin filament is made of a functional resin.
2 . The method of claim 1 , wherein the resin filament is made of a functional polymer material.
3 . The method of claim 2 , wherein the porous metal matrix is made of aluminum.
4 . The method of claim 3 , wherein each of the base layer and the build layer is formed as a combination of linear layers deposited by heating and extruding the resin filament through the nozzle,
wherein the fused deposition modeling 3D printer deposits the linear layers under an extrusion condition of the resin filament set such that a nozzle speed is 1.5 mm/s, a nozzle temperature is 220 degrees C., and a porous metal matrix heating temperature is 70 degrees C.
5 . The method of claim 1 , wherein the part is a gear comprising the porous metal matrix as an inner material and the functional resin as an outer material.