3D Printing Layer Segmentation for Speed and Accuracy
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Solution Overview
Problem
Existing methods for manufacturing three-dimensionally formed objects face a trade-off between manufacturing speed and accuracy, as increasing layer thickness to enhance speed compromises accuracy, and reducing thickness to improve accuracy slows down the process.
Innovation Solution
A method involving the lamination of layers, where a support layer is formed using a flowable resin composition ejected as liquid drops to determine the contour shape, allowing for high accuracy, and a constituent layer is formed with larger drops for the interior, enabling rapid and accurate manufacturing by decomposing and removing the support layer during heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the thickness of a layer is increased to increase the supply speed of flowable composition, then the manufacturing speed is improved, but the manufacturing accuracy deteriorates
Solution Approach 1:
The patent segments the layer formation process into two distinct types: support layers formed with small liquid drops for high accuracy contour definition, and constituent layers formed with large liquid drops for rapid material deposition. This segmentation allows each layer type to be optimized for its specific function, resolving the contradiction between speed and accuracy
Solution Approach 2:
The patent applies different drop sizes (different local qualities) to different regions and purposes: small drops are used where precision is needed (support layers and contour regions), while large drops are used where speed is prioritized (constituent layers and interior regions). This local differentiation enables simultaneous optimization of both manufacturing speed and accuracy
2Manufacturing precision
If the thickness of a layer is reduced to improve the manufacturing accuracy, then the manufacturing accuracy is improved, but the manufacturing speed is reduced
Solution Approach 1:
The patent divides the layer structure into support layers (thin, high accuracy) and constituent layers (thicker, high speed), allowing the overall manufacturing process to achieve both high accuracy contours and rapid production without the trade-off that plagues uniform layer approaches
Solution Approach 2:
The patent adds a dimensional distinction by using different drop sizes (small vs. large) rather than just varying layer thickness. This dimensional change in the deposition method enables simultaneous achievement of high accuracy (through small drops) and high speed (through large drops) in different regions
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 allows for the rapid production of three-dimensionally formed objects with high accuracy by using smaller drops for the support layer and larger drops for the constituent layer, improving both speed and precision while maintaining structural integrity.
Implementation Method 1
ejecting a flowable composition including a resin from an ejecting portion in the form of liquid drops
Implementation Method 2
solidifying the support layer
Implementation Method 3
the support layer is decomposed and removed
Implementation Method 4
the constituent layer is sintered
Data Source
AI summary
A method of manufacturing a three-dimensionally formed object in which the three-dimensionally formed object is manufactured by laminating layers to forma laminate, includes: forming a constituent layer corresponding to a constituent region of the three-dimensionally formed object; forming a support layer which is in contact with the constituent layer and supports the constituent layer by ejecting a flowable composition including a resin from an ejecting portion in the form of liquid drops; solidifying the support layer; and heating the laminate which is formed in the formation of the constituent layer, the formation of the support layer, and the solidification of the support layer.