3D Layered Object Printing With Melt-Away Containing Layers
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Solution Overview
Problem
Existing three-dimensional object manufacturing methods consume excessive materials, are limited to photosensitive materials, lack environmental sustainability, require manual intervention for object release, and have high operating costs.
Innovation Solution
A device and method utilizing a cooling system to control temperature, combined with selective deposition and irradiation of non-photosensitive materials like water and molten wax, to create layered objects with precise, homogeneous structures that spontaneously release at room temperature without solvents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photosensitive materials are used with selective exposure, then three-dimensional objects can be produced, but material consumption is excessive and operating costs are high
Solution Approach 1:
The patent changes the fundamental parameter of material state from liquid photosensitive resin to solid non-photosensitive material (such as wax or polymer). This parameter change eliminates the need for selective exposure and allows the material to be deposited in solid form, dramatically reducing material consumption and operating costs while maintaining manufacturing precision for three-dimensional object production.
Solution Approach 2:
The patent replaces the optical-mechanical system of selective laser exposure with a direct material deposition system. Instead of using light to selectively cure liquid material, the system directly deposits solid material layer by layer, eliminating the need for complex optical exposure mechanisms and reducing material waste from uncured portions.
2Ease of manufacture
If photosensitive materials are used, then selective exposure is possible, but the method is limited to photosensitive materials only
Solution Approach 1:
The patent creates a universal manufacturing system that can process multiple material types (wax, polymer, and other non-photosensitive solids) rather than being limited to photosensitive resins. The system uses general material deposition and melting mechanisms that work across different material categories, greatly enhancing adaptability and versatility while maintaining ease of manufacture through automated layer-by-layer construction.
3Manufacturing precision
If conventional materials are used, then three-dimensional objects can be produced, but environmental sustainability is compromised
Solution Approach 1:
The patent changes the material parameters to use environmentally friendly substances such as wax and polymer that can be melted and deposited without harmful chemicals. These materials eliminate the need for toxic solvents and photosensitive chemicals, maintaining manufacturing precision while significantly improving environmental sustainability and reducing harmful factors associated with the manufacturing process.
4Ease of operation
If reversibly solidified layers are used as support, then object release is achieved through temperature increase, but manual intervention and solvents are required
Solution Approach 1:
The patent implements a self-service release mechanism where the support layers automatically melt and release the three-dimensional object when the temperature is increased, without requiring manual intervention or chemical solvents. The system uses the material's own physical properties (melting point) to enable automated object release, enhancing ease of operation and eliminating the need for additional manual steps or chemical agents.
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
Reduces material consumption, expands material options, ensures precise and homogeneous printing, lowers costs, and enables solvent-free, environmentally friendly object release.
Implementation Method 1
a cooling system (7) designed to cool the printing chamber (6) bringing to a predetermined temperature, preferably a temperature lower than 0° C.
Implementation Method 2
a selective irradiation device (12) designed to generate a thermal radiation (13)
Implementation Method 3
the structural layer (G2) and the edges of the deposited material
Data Source
AI summary
The method for producing a three-dimensional layered object comprising the steps of: depositing, onto a support plane of a cooled platform, a first liquid which solidifies forming a first containing layer H1; depositing, onto the first containing layer H1, a second liquid which solidifies forming a first structural layer G2 of the three-dimensional object; the structural layer G2 is deposited in an area that has contours corresponding to the contours of a first section of the digital model of the three-dimensional object; forming a second containing layer H2 which completely surrounds the structural layer G2 in the directions X and Y; repeating the previous steps for all sections n of the three-dimensional model, thus producing an object formed by n superimposed structural layers G2, G3, . . . Gi, . . . Gn which is incorporated at the bottom and on the sides along the directions X and Y by n+1 containing layers H1, H2, . . . Hi, . . . Hn+1; melting the containing layers, hence freeing the three-dimensional layered object thus formed.