3D Structure Manufacturing via Permeation Prevention Agent
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Solution Overview
Problem
The existing manufacturing methods of three-dimensional structures using powder binding solutions face challenges with powder scattering and uniform layer formation due to solvent permeation, leading to reduced dimensional accuracy and mechanical strength.
Innovation Solution
A manufacturing method involving a three-dimensional formation composition with powders, a solvent, and a binder, where a binding solution is selectively applied using an ink jet method, and a permeation prevention step is performed using a permeation prevention agent to prevent solvent permeation, ensuring high dimensional accuracy and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a binding solution is discharged to a powder layer to bind powders, then the three-dimensional structure can be formed by laminating unit layers, but the solvent in the binding solution causes powder scattering and permeates into the lower layer, reducing dimensional accuracy and uniformity
Solution Approach 1:
A permeation prevention agent is applied to the surface of the formed layer before the binding solution is discharged. This preliminary action creates a barrier that prevents solvent from the subsequent binding solution from permeating into the lower layer, thereby maintaining dimensional accuracy while allowing rapid layer-by-layer formation to continue
Solution Approach 2:
The permeation prevention agent acts as an intermediary substance between the lower layer and the binding solution. It selectively allows the binding solution to reach the powder layer for binding while blocking the solvent from permeating into the lower layer, thus resolving the contradiction between formation efficiency and precision
2Stability of the object's composition
If a paste material containing liquid component is used to prevent powder scattering, then powder scattering is reduced, but the liquid component permeates into the lower layer when forming layers, disturbing uniform layer formation
Solution Approach 1:
The process is segmented into distinct functional steps: first applying a permeation prevention agent to protect the lower layer, then discharging the binding solution to form the upper layer. This segmentation allows each step to perform its specific function without interfering with the other, maintaining uniform layer formation while simplifying the overall manufacturing process compared to using paste materials
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
The method achieves high dimensional accuracy and mechanical strength by preventing solvent permeation and scattering, allowing for the formation of complex structures with improved reproducibility and uniformity.
Implementation Method 1
discharging a binding solution containing a binding agent to the layers
Implementation Method 2
performing a permeation prevention step of preventing the solvent from permeating the layers
Data Source
AI summary
Provided is a manufacturing method of a three-dimensional structure which manufactures a three-dimensional structure by laminating layers, the method including: forming the layers using a three-dimensional formation composition containing three-dimensional formation powders, a solvent, and a binder; discharging a binding solution containing a binding agent to the layers; and performing a permeation prevention step of preventing the solvent from permeating the layers, at least on a part of the layers to which the binding solution is discharged. It is preferable that the permeation prevention process is selectively performed with respect to an area of the layers to which the binding solution is not discharged.