3D Shaped Article Layering for Low-Load Support Separation
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Solution Overview
Problem
Existing three-dimensional shaped article production methods face challenges in separating sintered bodies from supports without damaging the article, due to integration issues and high separation loads.
Innovation Solution
A method involving the formation of layers with different binder strengths and decomposition temperatures, along with a separation promotion step using electromagnetic wave irradiation, allows for easy separation of the second layer from the support without damaging the article, by controlling the binding forces and using a titania layer for enhanced decomposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a three-dimensional shaped article is formed on a support by stacking layers and sintering, then the article can be produced with complex geometry, but the sintered body becomes integrated with the support making separation difficult
Solution Approach 1:
The patent divides the support structure into multiple layers with different binder strengths. The first layer (support layer) has a weaker binder that allows easy separation, while subsequent layers have stronger binders for article integrity. This segmentation enables the article to be separated from the support without damage.
Solution Approach 2:
Different regions of the support structure have different binder properties. The first layer uses a binder with lower binding force and lower decomposition temperature specifically at the interface with the support, while upper layers use binders with higher binding forces. This local differentiation allows easy separation at the support interface while maintaining article strength elsewhere.
2Strength
If a strong binder is used to ensure article integrity, then the article structure is maintained during production, but the separation load increases and may damage the article
Solution Approach 1:
The binder system is segmented into multiple types with different strengths. The first layer uses a weak binder for easy separation, while subsequent layers use progressively stronger binders. This creates a gradient where the article maintains integrity through strong upper layers but separates easily from the support through the weak first layer.
Solution Approach 2:
The binder decomposition temperature and binding force parameters are changed across different layers. The first layer binder has a lower decomposition temperature and binding force, while upper layer binders have higher values. This parameter differentiation allows the article to withstand production forces while enabling easy separation.
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 load required for separation and prevents damage to the three-dimensional shaped article by controlling binder forces and utilizing electromagnetic waves for efficient separation.
Implementation Method 1
the decomposition temperature of the binder contained in the first composition is lower than the decomposition temperature of the binder contained in the second composition
Implementation Method 2
the support is configured to be capable of transmitting an electromagnetic wave, and the separation promotion step is an electromagnetic wave irradiation step of irradiating the first composition with an electromagnetic wave through the support
Implementation Method 3
a first layer formation step of forming a first layer on a support by supplying a first composition containing first particles and a binder
Implementation Method 4
a sintering step of sintering the second layer is performed
Data Source
AI summary
A three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers to form a stacked body includes a first layer formation step of forming a first layer on a support by supplying a first composition containing first particles and a binder, a second layer formation step of forming a second layer composed of one layer or a plurality of layers on the first layer by supplying a second composition containing second particles and a binder, and a separation step of separating the second layer from the support through the first layer, wherein after the separation step, a sintering step of sintering the second layer is performed.