3D Printing Layer Height Control for Dimensional Accuracy
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Solution Overview
Problem
The stacking method for producing three-dimensional shaped articles often results in decreased dimensional accuracy due to deviations in layer thickness, which becomes more significant as the number of stacked layers increases, affecting the overall precision of the final product.
Innovation Solution
A method involving the formation of layers using a composition containing particles and a solvent, where the sacrificial part forming composition is adjusted based on the height measurements of previous layers to ensure accurate thickness, allowing for the adjustment of the sacrificial part forming composition's supply amount per unit area to achieve desired layer heights, and using a dispenser to eject the composition in a predetermined pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the stacking method is used to rapidly produce three-dimensional shaped articles, then productivity is improved, but manufacturing precision deteriorates due to layer thickness deviations
Solution Approach 1:
The patent implements a feedback control mechanism where the thickness of each layer is measured after formation, and the measurement result is used to adjust the supply amount of composition for the next layer. This closed-loop control compensates for thickness deviations, maintaining dimensional accuracy while enabling rapid multi-layer production
Solution Approach 2:
The patent adjusts the supply amount of composition for the (n+1)th layer based on the measured thickness of the n-th layer before actually forming the (n+1)th layer. This preliminary adjustment ensures that cumulative thickness errors are corrected in advance, preventing dimensional accuracy deterioration
2Manufacturing precision
If the supply amount of sacrificial part forming composition is increased to compensate for thickness deviations, then manufacturing precision is improved, but loss of substance increases
Solution Approach 1:
The patent dynamically changes the supply amount parameter of the sacrificial part forming composition based on actual measured thickness values. Instead of using a fixed or uniformly increased supply amount, the system adjusts the composition supply precisely according to the specific thickness deviation detected in each layer, minimizing material waste while achieving dimensional accuracy
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 dimensional accuracy of the three-dimensional shaped articles by allowing for precise control of layer thickness and surface shape, improving the productivity and quality of the final product by maintaining high accuracy across multiple layers.
Implementation Method 1
a layer formation step of forming each layer in a predetermined pattern by ejecting a composition containing particles using a dispenser
Implementation Method 2
a measurement step of determining the height of the layer at a plurality of places
Implementation Method 3
a bonding step of subjecting a stacked body including a plurality of layers to a bonding treatment for bonding the particles
Data Source
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AI summary
A three-dimensional shaped article production method according to the invention includes a step of forming a layer by ejecting a composition containing particles using a dispenser, a step of determining the height of the layer, and a step of subjecting a stacked body including a plurality of layers to a bonding treatment for bonding the particles, wherein the stacked body includes a layer which has a first portion corresponding to a portion to become an actual body part of the three-dimensional shaped article to be formed using an actual body part forming composition, and a second portion corresponding to a portion to become a sacrificial part to be formed using a sacrificial part forming composition, and in the case where an n-th layer has the second portion and the second portion of an (n+1)th layer is formed on at least part of the surface of the second portion of the n-th layer, the supply amount of the sacrificial part forming composition to be ejected onto the second portion of the n-th layer in the step of forming the (n+1)th layer is adjusted based on the information of the height of the surface of the second portion of the n-th layer.