3D Structure Manufacturing via Layered Molecular Orientation
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Solution Overview
Problem
Existing three-dimensional structure manufacturing methods lack the ability to freely control physical properties, limiting design flexibility and material selection for three-dimensional structures.
Innovation Solution
A method involving the repeated formation of layers containing chemical substances and molecular orientation, using techniques such as FDM and photo-orientation, to align molecules and achieve anisotropic properties, allowing for precise control of thermophysical, photophysical, and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional three-dimensional structure manufacturing methods are used, then manufacturing process is simple, but physical properties of the three-dimensional structure cannot be freely controlled
Solution Approach 1:
The manufacturing process is divided into multiple cycles, each consisting of layer formation followed by molecular orientation. This segmentation allows independent control of physical properties for each layer while building up the three-dimensional structure, enabling freedom in property control without requiring complete process redesign
Solution Approach 2:
Molecular orientation is performed as a preliminary action within each manufacturing cycle, before the next layer is formed. This preliminary molecular alignment ensures that physical properties are established in advance for each layer, allowing precise control of thermophysical, photophysical, and mechanical properties throughout the structure
2Adaptability or versatility
If molecular orientation is performed after layer formation, then physical properties can be controlled, but manufacturing time increases
Solution Approach 1:
The layer formation process and molecular orientation process are merged into a single integrated manufacturing cycle. Layer formation is followed immediately by molecular orientation in the same cycle, eliminating the need for separate post-processing steps and reducing overall manufacturing time while maintaining property control
Solution Approach 2:
The manufacturing process maintains continuous useful action by performing molecular orientation immediately after layer formation without idle time between steps. This continuous cycle of layer formation followed by molecular orientation ensures efficient time utilization while achieving precise physical property control
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
Enables the creation of three-dimensional structures with tailored physical properties, enhancing design freedom and material diversity, and enabling applications in optical elements, construction, and other specialized fields.
Implementation Method 1
a step of irradiating the at least two layers of photopolymerizable films with light under non-oxygen atmosphere to copolymerize the photopolymerizable monomer
Implementation Method 2
a compound resin material which contains a plurality of types of resin materials and in which first layers and second layers are repeatedly disposed in a buildup direction
Data Source
Figure 1(A)~1(F)
Figure 2(A)~2(D)
Figure 3(A)~3(J)
AI summary
A three-dimensional structure manufacturing method capable of freely controlling physical properties of a three-dimensional structure is provided. There is provided the three-dimensional structure manufacturing method including: forming a layer containing at least one type of chemical substance; and orienting molecules of the at least one type of chemical substance, the forming the layer and the orienting the molecules being repeated a plurality of times.