3D Printing Segmented Curing to Control Warpage
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Solution Overview
Problem
Existing three-dimensional forming methods often result in warpage due to contraction issues when melted thermoplastic materials are cured, making it difficult to create objects with desired shapes.
Innovation Solution
A method involving a three-dimensional forming apparatus that performs a first forming process to create parallel segments, followed by curing, and then a second forming process to connect these segments with a nozzle, allowing for controlled material deposition and curing to minimize warpage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If melted thermoplastic material is extruded and cured in a single continuous process, then productivity is improved, but manufacturing precision deteriorates due to warpage from contraction
Solution Approach 1:
The forming process is divided into multiple segments: a first portion is formed and cured, then a second portion is formed and cured separately. This segmentation allows each portion to be cured independently, preventing warpage while maintaining efficient production. The curing unit cures the first portion before the second portion is formed, ensuring each segment stabilizes without causing overall structure distortion.
2Loss of time
If the entire three-dimensional object is formed and cured at once, then manufacturing time is reduced, but manufacturing precision deteriorates due to contraction during curing
Solution Approach 1:
The first portion of the three-dimensional object is formed and cured in advance before the second portion is added. This preliminary curing allows the first portion to stabilize and set its shape before additional material is introduced, preventing contraction-induced warpage while maintaining an efficient multi-stage process that minimizes total forming time.
3Productivity
If continuous material deposition is performed, then productivity is improved, but manufacturing precision deteriorates due to uncontrolled contraction forces
Solution Approach 1:
The forming process uses periodic action by alternating between deposition phases and curing phases. The curing unit cures the first portion, then the second portion is deposited and cured separately. This periodic alternation between forming and curing operations allows contraction forces to be managed in discrete stages, maintaining shape control while preserving production efficiency through continuous operation cycles.
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 reduces warpage in the formed objects by dispersing the curing and contraction forces across multiple segments, enabling the creation of three-dimensional objects with improved dimensional accuracy and precision.
Implementation Method 1
a melted thermoplastic material is extruded from an extruding nozzle
Implementation Method 2
a nozzle to eject a forming material onto a forming surface of a forming base
Implementation Method 3
a probability that warpage occurs due to contraction when the melted material is cured
Data Source
AI summary
The method of forming a three-dimensional object includes: a first forming process of causing a nozzle to eject a forming material onto a forming surface of a forming base and forming a first portion and a second portion such that the first portion and the second portion are away from each other in a first direction in parallel to the forming surface; a curing process of curing the first portion and the second portion; and a second forming process of causing the nozzle to eject the forming material between the first portion and the second portion and forming a third portion that has a shape that successively connects an end surface of the first portion in the first direction to an end surface of the second portion in the first direction, after the curing process.