3D Printed Support Structure with Gaps for Heavy Resin Models
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Three-dimensional layered modeling apparatuses face challenges in supporting large, heavy modeled articles during the shaping process, particularly with non-fluid light curable resins and powdery molding methods, leading to deformation, instability, and increased burden on workers when removing supports or powders.
Innovation Solution
A support forming method and three-dimensional modeled object design that incorporates strategically placed supports and gaps to prevent deformation and instability, allowing for easy detachment and reduction of damage during post-processing, using non-fluid shaping materials like powders or resins kept below their melting temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If supports are provided to prevent deformation of large, heavy modeled articles, then manufacturing precision is improved, but device complexity increases and ease of operation deteriorates due to difficult support removal
Solution Approach 1:
The support structure is divided into multiple detachable segments rather than a single monolithic support. This allows the support to be removed in parts, reducing the complexity and difficulty of support removal while maintaining its function of preventing deformation during the molding process
Solution Approach 2:
The support structure is designed to be extractable from the molded article after curing. The support can be removed from the cured article without damaging the final product, transforming the support from a permanent structural element to a temporary auxiliary component that serves its purpose during manufacturing only
2Reliability
If supports are made large and robust to support heavy modeled articles, then reliability of support function is improved, but weight of support increases making it harder to handle and remove
Solution Approach 1:
The support structure concentrates its strength and material only in the specific areas where load-bearing is necessary, rather than uniformly throughout the entire support. This localized reinforcement maintains the reliability of the support function for heavy articles while minimizing the overall weight and making the support easier to handle and remove
3Manufacturing precision
If supports are provided to prevent undercut in overhanging portions, then manufacturing precision is improved, but the support becomes an obstacle requiring complex removal procedures
Solution Approach 1:
The support structure is designed as a temporary, disposable component that is easily removed after serving its purpose of preventing undercut during curing. The support may be made from materials that allow for simple removal methods, such as melting, dissolving, or mechanical detachment, reducing the complexity of the overall system
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 effectively supports large, heavy modeled articles, reduces deformation and damage during post-processing, and simplifies the removal process, minimizing worker burden and preventing unwanted contact or falling of articles.
Implementation Method 1
light (for example, a UV laser) which is controlled by a computer so as to obtain a desired pattern is selectively irradiated to a liquid surface of a liquid light curable resin (a fluid material) charged in a molding bath so as to cure the light curable resin
Implementation Method 2
the light curable resin of the layer cured by the irradiation of light is maintained in a solid state at a temperature lower than a melting temperature
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3C
AI summary
The present invention is a three-dimensional modeled object including: a shaping material which is layered on a fabrication table ; a modeled article which is formed inside the shaping material; and a support which is formed inside the shaping material and is formed with a predetermined gap with respect to the modeled article.