3D Printer Layer Curing for Transparent, Support-Free Molding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing three-dimensional printing methods using resin materials result in "build lines" on the surface of molded objects, leading to reduced transparency and the need for support members in complex shapes, particularly in transparent objects and those with overhanging or undercut portions.
Innovation Solution
A manufacturing method and control program for a three-dimensional printer that involves forming and adhering uncured layers before complete curing, utilizing the viscosity of the molding material to reduce gaps between layers, eliminating the need for support members and enhancing transparency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the uncured layer curing process is completed before forming the next layer, then the molded layer is fully cured and structurally stable, but gap portions form between adjoining molded layers causing build lines
Solution Approach 1:
The patent applies preliminary action by initiating the curing process of the uncured layer before the next layer is formed, but completing it after the next layer is formed. This allows the lower layer to maintain viscosity during the critical adhesion phase, enabling it to fill gaps at outer edge portions, and then complete curing afterward to achieve both gapless surfaces and structural stability.
2Reliability
If support members are provided for overhanging portions, then the molded object maintains structural integrity during printing, but the manufacturing process becomes complicated and productivity decreases
Solution Approach 1:
The patent changes the temporal parameter of the curing process by extending it across layer boundaries. The uncured layer curing process starts before the next layer formation and completes after, which dynamically adjusts the viscosity parameter of the molding material during the critical adhesion period. This eliminates the need for support members as the material itself provides temporary structural support through controlled viscosity changes.
3Reliability
If the nozzle discharges molding material after the previous layer is fully cured, then the layer structure is stable, but outer edge portions do not adhere properly forming build lines
Solution Approach 1:
The patent applies preliminary action by starting the curing process of the uncured layer before the next layer is formed, but completing it after the next layer is formed. This allows the lower layer to maintain viscosity during the critical adhesion phase, enabling it to fill gaps at outer edge portions, and then complete curing afterward to achieve both gapless surfaces and structural stability.
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 produces molded objects with smoother surfaces and higher transparency by minimizing "build lines" and allows for complex shapes without support structures, improving producibility and transparency.
Implementation Method 1
an uncured layer curing process of curing the one layer of the molded layer
Implementation Method 2
utilizing the viscosity of the molding material to reduce gaps between layers
Data Source
Figure 1
Figure 2
Figure 3
AI summary
It is the subject of the present invention to provide a manufacturing method of a molded object using a three-dimensional printer for creating a molded object with favorable transparency and a control program for a three-dimensional printer. For solving the subject, the manufacturing method of a molded object using a three-dimensional printer manufactures a molded object by sequentially repeating an uncured layer forming process (S1) of forming one layer of a molded layer with an uncured molding material and an uncured layer curing process (S2) of curing the one layer of the molded layer, wherein the uncured layer curing process (S2) is finished prior to the final curing of the one layer of the molded layer formed by the immediately preceding uncured layer forming process (S1) and the uncured layer forming process (S1) for forming the next one layer of the molded layer is executed.