3D Printing Peeling Layer and Brim Configuration
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Solution Overview
Problem
Existing methods for manufacturing three-dimensional shaped objects often result in warpage and damage during separation from the shaping stage due to strong adhesion, as they rely on circular brims that can cause damage when separating the object from the stage.
Innovation Solution
A method involving the creation of a peeling layer, a shaped object, and a brim layer using different shaping materials, where the peeling layer and brim layer are designed to be separated from the shaped object, improving peeling properties and preventing warpage by adjusting the contact strength and brim layer size based on the object's dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a circular brim is shaped to prevent warpage by contacting the outer periphery of the shaping target layer, then warpage is prevented, but the shaped object may be damaged when separated from the stage due to strong adhesion
Solution Approach 1:
The patent divides the support structure into two distinct segments: a peeling layer that remains strongly adhered to the stage for warpage prevention, and a brim layer that is easily separable from the shaped object. This segmentation allows each layer to fulfill its specific function without compromising the other - the peeling layer provides stability during shaping while the brim layer enables clean separation.
Solution Approach 2:
The patent applies different material properties to different parts of the support structure. The peeling layer uses a first shaping material with specific adhesion characteristics for strong stage bonding, while the brim layer uses a second shaping material with different properties that facilitate easy separation from the shaped object. This local differentiation of material qualities resolves the contradiction between strong adhesion for warpage prevention and easy separation.
2Stability of the object's composition
If a brim layer is shaped to prevent warpage, then shaping stability is improved, but the contact strength between the brim layer and shaped object may cause damage during separation
Solution Approach 1:
The support structure is segmented into a peeling layer for shaping stability and a brim layer for easy separation. The peeling layer maintains strong contact with the stage during the shaping process to prevent warpage, while the brim layer is designed with different material properties that allow it to be easily peeled away from the completed shaped object without damage.
Solution Approach 2:
The patent changes the material parameters between the peeling layer and brim layer. The first shaping material in the peeling layer has adhesion properties optimized for strong stage bonding, while the second shaping material in the brim layer has properties that reduce adhesion to the shaped object, facilitating easy separation. This parameter change resolves the contradiction between shaping stability and separation ease.
3Ease of operation
If the peeling layer and brim layer are configured to be separated from the shaped object, then peeling properties are improved, but the structure complexity increases
Solution Approach 1:
The patent implements a two-layer segmented structure (peeling layer and brim layer) that improves peeling properties by allowing the brim layer to be easily separated from the shaped object. While this adds structural complexity, the segmentation enables functional differentiation that resolves the contradiction between maintaining shaping stability and achieving easy separation.
Solution Approach 2:
Different material qualities are applied locally in the peeling layer and brim layer to achieve distinct functions. The peeling layer provides strong stage adhesion for shaping stability, while the brim layer provides easy separability. This local quality differentiation improves peeling properties while managing the inherent structural complexity through functional specialization.
Data Source
AI summary
A method of manufacturing a three-dimensional shaped object includes: a first step of shaping a peeling layer at a stage by ejecting a first shaping material; a second step of shaping a shaped object by ejecting a second shaping material and stacking a shaping layer at the peeling layer; and a third step of shaping, at the peeling layer, a brim layer adjacent to and in contact with at least a part of an outer shell of a lowermost layer of the shaped object by ejecting a third shaping material. The peeling layer and the brim layer are layers configured to be separated from the shaped object shaped by the second step.