3D Printing Layer Temperature Gradient to Reduce Warp Deformation
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Solution Overview
Problem
The selective laser sintering method often results in warp deformation of three-dimensional shaped objects due to shrinkage stress from reduced voids between powder particles, leading to shape inaccuracies.
Innovation Solution
The method involves forming at least one prior solidified layer under a higher temperature condition than subsequent layers, with the prior layer being formed before the subsequent layer, to counteract inward stress and reduce warp deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a powder layer is irradiated with a light beam to form a solidified layer through sintering or melting, then a three-dimensional shaped object can be manufactured with complicated contour shape in short time, but shrinkage stress occurs due to reduced void between particles causing warp deformation
Solution Approach 1:
The patent applies preliminary action by forming a prior solidified layer under higher temperature conditions before forming subsequent solidified layers. This preliminary high-temperature layer creates outward stress that counteracts the inward shrinkage stress from subsequent layers, preventing warp deformation while maintaining rapid manufacturing capability
Solution Approach 2:
The patent changes the temperature parameter across different layers, with prior layers formed at higher temperatures and subsequent layers at lower temperatures. This parameter variation creates differential stress states that compensate for shrinkage effects, resolving the contradiction between manufacturing speed and shape 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 effectively minimizes warp deformation in the final three-dimensional shaped object by creating an offset stress effect, ensuring a more accurate and stable shape.
Implementation Method 1
forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing a sintering of the predetermined portion of the powder
Implementation Method 2
a sintering of the predetermined portion of the powder or a melting and subsequent solidification of the predetermined portion
Data Source
AI summary
There is provided a manufacturing method of a three-dimensional shaped object, the method being capable of reducing a warp deformation of the three-dimensional shaped object. The manufacturing method according to an embodiment of the present invention produces a three-dimensional shaped object by alternate repetition of a powder-layer forming and a solidified-layer forming on a base plate, wherein the forming of at least one prior solidified layer is performed under a higher temperature condition than that for the forming of a subsequent solidified layer, the at least one prior solidified layer being formed prior to the subsequent solidified layer.