3D Forming Layers With Selective Sintering of Support Particles
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Solution Overview
Problem
Existing methods for manufacturing three-dimensionally formed objects using flowable compositions often result in excessive sintering or melting of regions outside the intended object, leading to increased load and inefficiency in subsequent operations.
Innovation Solution
A method involving the formation of layers using a flowable composition containing constituent material particles and support portion-forming particles, where energy is imparted to achieve temperatures above the sintering threshold for the constituent material particles but below that of the support portion-forming particles, preventing unnecessary sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If energy is imparted to sinter the constituent material particles, then the three-dimensionally formed object is successfully manufactured, but the support portion-forming particles are also sintered due to heat generation, increasing the load of subsequent extracting operations
Solution Approach 1:
The patent applies different thermal properties to different regions of the layer. The constituent material particles are designed with a lower sintering temperature than the support portion-forming particles, allowing selective sintering of the object region while keeping the support region unsintered. This local differentiation of material properties enables the contradiction to be resolved by targeting energy input to achieve desired sintering in the object while avoiding sintering in the support portion.
Solution Approach 2:
The patent changes the sintering temperature parameter between constituent material particles and support portion-forming particles. By selecting materials with different sintering temperatures and controlling the energy input to fall within a specific range (above the sintering temperature of constituent particles but below that of support particles), the process achieves selective sintering. This parameter differentiation allows the extracting operation to proceed with reduced load since the support portion remains unsintered.
2Reliability
If energy is imparted at high intensity to ensure complete sintering of the three-dimensionally formed object, then manufacturing reliability is improved, but excessive heat causes sintering of surrounding regions, reducing productivity
Solution Approach 1:
The patent optimizes the energy input parameters by establishing a specific temperature window for the sintering process. The energy intensity is controlled to deliver temperatures above the sintering point of constituent material particles (ensuring complete sintering and reliability) but below the sintering point of support portion-forming particles (preventing unnecessary sintering). This precise parameter control achieves both reliability and productivity goals.
Solution Approach 2:
The patent performs preliminary design of the layer composition before the sintering process, selecting constituent material particles and support portion-forming particles with specifically different sintering temperatures. This preliminary material selection creates a built-in mechanism that prevents excessive sintering during the energy imparting step, eliminating the need for additional post-manufacturing steps to remove or modify sintered support portions.
3Manufacturing precision
If the sintering temperature is raised to ensure complete sintering of all particles, then manufacturing precision is improved, but the support portion becomes difficult to extract, increasing operation complexity
Solution Approach 1:
The patent creates local quality differentiation in the layer by using constituent material particles with lower sintering temperatures than support portion-forming particles. This allows the sintering process to selectively complete sintering of the object region while leaving the support portion in an unsintered or lightly sintered state, maintaining its extractability and reducing operation complexity.
Solution Approach 2:
The patent changes the sintering temperature parameter of the support portion-forming particles to be higher than that of constituent material particles. By controlling the energy input to target the lower temperature range, complete sintering of the object is achieved while the support portion remains sufficiently unsintered to facilitate easy extraction, thereby reducing extracting operation complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the number of steps required after the three-dimensionally formed object is created, minimizing load and enhancing efficiency by preventing excessive sintering of support portions.
Implementation Method 1
the energy is imparted such that a temperature of the constituent material particles and a temperature of the support portion-forming particles are equal to or higher than a sintering temperature of the constituent material particles and are lower than a sintering temperature of the support portion-forming particles
Data Source
AI summary
A method of manufacturing a three-dimensionally formed object includes: forming a layer using a flowable composition including constituent material particles of a three-dimensionally formed object and a flowable composition including support portion-forming particles for forming a support portion which supports the three-dimensionally formed object during the formation of the three-dimensionally formed object; and imparting energy to the constituent material particles and the support portion-forming particles, in which in the imparting of the energy, the energy is imparted such that a temperature of the constituent material particles and a temperature of the support portion-forming particles are equal to or higher than a sintering temperature of the constituent material particles and are lower than a sintering temperature of the support portion-forming particles.