3D Printed Modeling Layers for Low-Warpage Easy Release
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Solution Overview
Problem
In material extrusion 3D printing, the warpage of the base modeling layer can lead to modeling defects, and the separation of the formed object from the modeling sheet is time-consuming, often requiring several hours due to strong welding between the object and the sheet.
Innovation Solution
A method using a 3D printer with a modeling stage and a placement surface, where at least one first modeling layer is formed on a modeling sheet using a first thermoplastic resin with an inorganic filler, and a second modeling layer is formed using a second thermoplastic resin that is weldable with the first, allowing for reduced warpage and easier separation by using different materials for each layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a modeling sheet is used to reduce warpage of the base modeling layer, then warpage is reduced, but the modeled object becomes firmly welded to the modeling sheet requiring great amount of time for separation
Solution Approach 1:
The invention segments the modeled object into multiple layers with different materials. The first modeling layer (in contact with modeling sheet) uses a material that welds strongly to reduce warpage, while the second modeling layer uses a different material that does not weld to the first layer, enabling easy separation. This segmentation allows simultaneous achievement of warpage reduction and easy separation.
Solution Approach 2:
The invention applies different material properties to different parts of the modeled object. The first modeling layer has properties optimized for welding to the modeling sheet (warpage reduction), while the second modeling layer has properties optimized for non-welding (easy separation). This local differentiation of material quality resolves the contradiction between strong adhesion and easy separation.
2Stability of the object's composition
If the same material is used for all modeling layers, then material consistency is maintained, but separation from the modeling sheet becomes time-consuming
Solution Approach 1:
The invention divides the modeled object into segmented layers with different materials. The first layer uses a material consistent with welding requirements for warpage reduction, while the second layer uses a different material for easy separation. This segmentation allows material consistency within each functional layer while achieving overall separation efficiency.
Solution Approach 2:
The invention uses composite material construction where the modeled object consists of multiple materials with different properties. The first modeling layer material and second modeling layer material are deliberately different to achieve both warpage reduction through strong welding and easy separation through non-welding properties.
3Manufacturing precision
If a modeling sheet is used to support the modeled object during formation, then warpage is reduced, but the separation process requires five or more hours for large objects
Solution Approach 1:
The invention segments the modeled object into layers with different material properties. The first layer maintains strong adhesion to the modeling sheet for warpage reduction, while the second layer is designed for rapid separation. This segmentation dramatically improves separation speed from five+ hours to a much shorter duration.
Solution Approach 2:
The invention changes the material parameters of different modeling layers. The first modeling layer uses material parameters optimized for strong welding (low separation ease), while the second modeling layer uses material parameters optimized for weak adhesion (high separation ease). This parameter differentiation enables rapid separation while maintaining warpage reduction.
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 warpage and significantly shortens the time required to separate the modeled object from the modeling sheet, achieving faster production while maintaining reduced warpage compared to methods without a modeling sheet.
Implementation Method 1
the first modeling layer material includes a first thermoplastic resin and an inorganic filler... the first modeling layer is formed on a surface of a modeling sheet... using a molten product of a first modeling layer material
Implementation Method 2
the second modeling layer material includes a second thermoplastic resin that is weldable with the first thermoplastic resin... forming at least one second modeling layer on the at least one first modeling layer
Data Source
AI summary
The present invention provides a method of producing a modeled object by material extrusion using a 3D printer, the 3D printer including a modeling stage having a placement surface for placing the modeled object thereon, the method including: forming at least one first modeling layer on a surface of a modeling sheet disposed on the placement surface, using a molten product of a first modeling layer material; and forming at least one second modeling layer on the at least one first modeling layer, using a molten product of a second modeling layer material, wherein the first modeling layer material is different from the second modeling layer material.