3D Printing Binder Distribution for Contour Strength
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Solution Overview
Problem
Three-dimensional shaped objects manufactured using existing methods often lack sufficient mechanical strength, particularly in contour portions, leading to issues like chipping due to inadequate binder distribution.
Innovation Solution
A method and apparatus for manufacturing three-dimensional shaped objects where the binder liquid is discharged with varying amounts per unit area in contour and non-contour regions of the powder layer, ensuring stronger binding at critical surface areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a uniform amount of binder liquid is discharged to all regions of the powder layer, then the manufacturing process is simple, but the mechanical strength of contour portions is insufficient leading to chipping
Solution Approach 1:
The patent applies local quality by discharging binder liquid with different amounts per unit area to different regions: contour portions receive a first discharging amount while non-contour portions receive a second discharging amount. This localized differentiation ensures that contour portions, which are more prone to chipping, receive sufficient binder for strength, while maintaining manufacturing feasibility through controlled regional variation.
2Reliability
If a larger amount of binder liquid is discharged to contour portions, then the mechanical strength and resistance to chipping improve, but the overall binder consumption increases
Solution Approach 1:
The patent optimizes binder liquid consumption by applying local quality principles: contour portions receive a first discharging amount specifically tailored to prevent chipping, while non-contour portions receive a second discharging amount that is optimized for their lower susceptibility to damage. This regional differentiation ensures reliable chipping resistance where needed while minimizing unnecessary binder consumption in areas where it is less critical.
3Manufacturing precision
If the binder liquid discharging amount varies by region, then the manufacturing precision and surface quality improve, but the control complexity increases
Solution Approach 1:
The patent achieves high manufacturing precision and surface quality by discharging binder liquid with different amounts per unit area to contour and non-contour portions. The control system manages this complexity by implementing a straightforward regional differentiation approach: contour portions receive a first discharging amount and non-contour portions receive a second discharging amount, ensuring optimal surface quality and dimensional accuracy without excessive system complexity.
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 approach enhances the mechanical strength of the object's surface, prevents shape defects, and facilitates easier handling and processing by optimizing binder distribution, resulting in improved quality, accuracy, and texture.
Implementation Method 1
a binder liquid containing a binder for binding the powders to one another
Data Source
AI summary
Provided is a method for manufacturing a three-dimensional shaped object, the manufacturing method including: a powder layer formation step of disposing powders containing a forming material of the three-dimensional shaped object in a layer shape and forming a powder layer having a predetermined thickness; and a molded body formation step of discharging, to the powder layer, a binder liquid containing a binder for binding the powders to one another, and forming a molded body in which the powders are bound to one another. In the molded body formation step, in a formation region of the molded body in the powder layer, a discharging amount of the binder liquid per unit area to a first formation region that is a contour portion of the formation region and a discharging amount of the binder liquid per unit area to a second formation region other than the contour portion are discharging amounts different from each other.