3D Printed Object Separation via Segmented Support Structures
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Solution Overview
Problem
Existing three-dimensional formed object manufacturing methods face challenges in efficiently separating the formed object from the forming table due to a bed configuration that is integrally connected and not efficient, leading to difficulties in removing the bed from the object.
Innovation Solution
A manufacturing method involving a forming apparatus that uses a flat screw to dispose and melt material, forming a substrate layer with separated structures on the forming table, allowing the three-dimensional formed object to be supported by these structures while minimizing contact area, thereby simplifying separation and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a bed is formed by applying resin material in a mesh-shape using a single brush-stroke to cover the base surface, then the strength of the bed is increased and the contact area with the forming table and three-dimensional formed object is increased, but the separation of the formed object from the forming table and the removal of the bed from the formed object become difficult
Solution Approach 1:
The bed is divided into multiple separate structures (first structures and second structures) arranged in a matrix pattern, rather than forming a continuous mesh. This segmentation reduces the overall contact area between the bed and both the forming table and the formed object, making separation and removal easier while maintaining sufficient support strength through the distributed structure arrangement.
2Shape
If a bed is formed using complicated nozzle scanning in a zigzag pattern, then the bed can be formed to cover the base surface, but the forming process is not efficient
Solution Approach 1:
The bed structures are formed in advance before the three-dimensional formed object is created. By pre-forming the support structures in a systematic matrix arrangement, the subsequent object formation process is simplified and accelerated, as the support framework is already in place and does not require complex real-time scanning adjustments.
Solution Approach 2:
The bed formation process is segmented into discrete first structures and second structures arranged in rows and columns. This segmented approach allows for more efficient forming compared to continuous zigzag scanning, as each structure can be formed independently and systematically, improving overall productivity while achieving complete base surface coverage.
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 method enhances the precision of the formed object by reducing deformation and surface roughness, and simplifies the separation and removal of the formed object and its substrate layer from the forming table.
Implementation Method 1
a material P which is obtained by plasticizing and melting a thermoplastic material
Implementation Method 2
plasticizing and melting a thermoplastic material such as a resin
Data Source
AI summary
A manufacturing method of a three-dimensional formed object includes disposing a first forming material on a forming table to form a plurality of structures which are separated from each other, and disposing a second forming material for forming the three-dimensional formed object such that the three-dimensional formed object is supported by the plurality of structures in a state of being separated from the forming table.