3D Printing Layer Drying Control for Precision

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Solution Overview

Problem

Existing three-dimensionally formed object manufacturing methods face challenges in maintaining accuracy due to deformation of fluid material layers caused by the weight of upper layers, leading to reduced quality and accuracy in the final product.

Innovation Solution

A manufacturing apparatus that includes an ejecting portion for fluid material with particles and solvent, a stage for layer formation, an imaging portion to monitor solvent evaporation, and a determination portion to ensure sufficient solvent evaporation before adding subsequent layers, using changes in color or viscosity to adjust drying processes, thereby preventing horizontal spreading and deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If fluid material layers are laminated continuously without drying, then manufacturing productivity is improved, but manufacturing precision deteriorates due to horizontal spreading and deformation

Engineering Contradiction:
Improvemanufacturing productivityVSAvoidmanufacturing precision
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by drying each fluid material layer before laminating the next layer. The drying process removes solvent from the previously deposited layer, causing it to solidify and gain mechanical strength. This preliminary solidification prevents horizontal spreading when subsequent layers are added, thereby maintaining manufacturing precision while enabling continuous lamination for high productivity.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent implements periodic action through alternating deposition and drying cycles. Each layer undergoes a periodic sequence of: (1) deposition of fluid material containing solvent, (2) drying to remove solvent and solidify the layer, (3) lamination of the next layer. This periodic alternation between wet deposition and dry solidification maintains layer stability while enabling continuous manufacturing.

Inventive Principle:
Principle #19Periodic action

2Manufacturing precision

If solvent is completely volatilized before next layer, then manufacturing precision is improved, but loss of time increases due to extended drying period

Engineering Contradiction:
ImproveaccuracyVSAvoiddrying time
Core Design Contradiction:
Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent applies partial action by drying each layer to sufficient solidity for supporting the next layer, rather than requiring complete solvent removal. The drying process continues until the layer achieves adequate mechanical strength to prevent deformation under subsequent layers, which is sufficient for maintaining manufacturing precision without the need for exhaustive drying that would waste time.

Inventive Principle:
Principle #16Partial or excessive action

Solution Approach 2:

The patent ensures continuity of useful action by overlapping the drying process with the preparation and deposition of the next layer. While one layer is drying, the system can prepare the next layer material and position the deposition head, so that drying never completely stops the manufacturing process. This continuous workflow minimizes idle time while ensuring each layer is sufficiently dried.

Inventive Principle:
Principle #20Continuity of useful action

3Manufacturing precision

If drying process is extended, then manufacturing precision is improved by preventing deformation, but productivity decreases

Engineering Contradiction:
ImproveaccuracyVSAvoidmanufacturing productivity
Core Design Contradiction:
Manufacturing precisionVSProductivity

Solution Approach 1:

The patent applies preliminary action by implementing a standardized drying process for each layer that achieves sufficient solidity before the next layer is deposited. This preliminary drying ensures that each layer is prepared in advance with adequate strength to support subsequent layers, preventing deformation and maintaining precision without requiring extended overall drying time that would reduce productivity.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent utilizes parameter changes in the drying process, specifically controlling temperature and time parameters to achieve optimal drying efficiency. By adjusting these parameters, the system achieves sufficient layer solidity in minimal time, balancing manufacturing precision requirements with productivity maintenance.

Inventive Principle:
Principle #35Parameter changes

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 apparatus effectively suppresses deformation of fluid material layers, ensuring higher accuracy and quality in three-dimensionally formed objects by ensuring complete solvent evaporation before adding subsequent layers, thus maintaining the desired shape and structure.

Implementation Method 1

a drying portion that volatilizes the solvent included in the fluid material of the stage

Methodology Applied
Scientific EffectEvaporation: Evaporation

Implementation Method 2

an obtaining portion that obtains an image of the layer formed of the fluid material formed on the stage

Methodology Applied
Scientific EffectLight absorption and reflection:

Data Source

PatentEP3300875B1Three-dimensionally formed object manufacturing apparatus and method of manufacturing three-dimensionally formed object
Publication Date: 2019.07.31 SEIKO EPSON CORP
  • EP3300875B1 patent drawingFigure 1
  • EP3300875B1 patent drawingFigure 2
  • EP3300875B1 patent drawingFigure 3

AI summary

A three-dimensionally formed object manufacturing apparatus (2000) includes: an ejecting portion (1400) that ejects a fluid material including particles, which form a constituent material of a three-dimensionally formed object, and a solvent; a stage (120) on which a layer (501) formed of the fluid material, which is ejected from the ejecting portion (1400), is laminated; an obtaining portion that obtains an image of the layer formed of the fluid material formed on the stage; a drying portion (800) that volatilizes the solvent included in the fluid material of the stage (120); and a determination portion (400) that determines whether or not a predetermined amount or more of the solvent is volatilized based on the image obtained by the obtaining portion (830), in which a next layer (502) formed of the fluid material is laminated after the determination portion determines that the predetermined amount or more of the solvent is volatilized per formation of a predetermined layer in a laminating direction of the layer formed of the fluid material.