3D Printing Ink Segmentation for Smooth Surface Accuracy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for manufacturing three-dimensional shaped objects using powder and coupling liquid result in uneven outer surfaces and irregular steps due to ink spread, leading to reduced dimensional accuracy and surface smoothness.
Innovation Solution
A method involving the lamination of layers formed by ejecting and curing ink, including a curing resin, using a composition with powder particles, where an object formation ink and a sacrificial layer formation ink are used to create a boundary between penetration regions, with the sacrificial layer being easily removable and the object formation ink providing a smooth outer surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If coupling liquid is ejected to the powder layer, then the powder is coupled to form three-dimensional object, but the ink spread causes uneven outer surface and irregular steps
Solution Approach 1:
The patent segments the coupling liquid into multiple droplets with different functions: object formation ink for the main structure and sacrificial layer formation ink for the outer surface region. This segmentation allows each droplet type to be controlled independently, preventing the spread issues that cause uneven surfaces while maintaining effective powder coupling for object formation.
Solution Approach 2:
The sacrificial layer formation ink acts as an intermediary substance that temporarily fills the outer surface region during manufacturing. This intermediary material prevents direct contact and spread of the object formation ink at the outer surface, eliminating irregular steps. The sacrificial layer is later removed to reveal the smooth outer surface of the three-dimensional object.
2Strength
If coupling liquid penetrates to reach previously formed cross-section member, then layers are bonded together, but ink spread causes uneven outer surface
Solution Approach 1:
The patent divides the coupling liquid into functionally separate droplets: object formation ink that penetrates to bond layers internally, and sacrificial layer formation ink that occupies the outer surface region. This segmentation ensures that bonding occurs through ink penetration while the outer surface remains uniform, as the sacrificial layer prevents object formation ink from spreading at the surface.
Solution Approach 2:
Different regions of the powder layer are treated with different ink types: the object formation ink provides bonding strength through penetration to previously formed layers, while the sacrificial layer formation ink provides local surface quality control by occupying the outer surface region. This local differentiation allows simultaneous achievement of strong bonding and uniform outer surface.
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 prevents irregular steps and achieves high dimensional accuracy and a smooth outer surface for three-dimensional shaped objects by adjusting the infiltration rates of the inks and using hydrophilic sacrificial layer materials for efficient removal, enhancing the mechanical strength and productivity of the objects.
Implementation Method 1
ejecting and curing ink including a curing resin
Implementation Method 2
the object formation ink and the sacrificial layer formation ink penetrate into the layers while forming a boundary
Data Source
AI summary
In a method for manufacturing a three-dimensional shaped object in which layers formed by ejecting and curing ink including a curing resin are laminated, the method includes a layer forming process of forming the layers by using a composition for three-dimensional shaped object including powder for three-dimensional shaped object, and an ink ejecting process of ejecting an object formation ink and a sacrificial layer formation ink to the layers. In the ink ejecting process, the object formation ink and the sacrificial layer formation ink penetrate into the layers while forming a boundary between a region where the object formation ink penetrates in the layers and a region where the sacrificial layer formation ink penetrates into the layers.