3D Printing Support Structure Using Composite Material Patterns
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Solution Overview
Problem
Existing three-dimensional structure forming technologies face challenges in maintaining the strength of support structures while ensuring ease of removal, particularly in cases where only support material is used, leading to potential deterioration and shape variation over time.
Innovation Solution
The proposed solution involves a three-dimensional forming apparatus that uses a combination of model materials and support materials arranged in specific patterns, such as grid-like or gradation patterns, to create support structures that are both strong and easily removable, utilizing UV-curable resins and a controlled ejection and curing process to optimize support material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If only support material is used to form support structures, then ease of removal is improved, but strength and shape stability deteriorate over time
Solution Approach 1:
The patent applies composite materials by combining model material and support material in a layered structure. The model material provides strength and shape stability to the support structure, while the support material enables easy removal. This composite approach allows the support structure to simultaneously achieve both strength and ease of removal, resolving the technical contradiction between these two properties.
2Ease of manufacture
If support material is used alone, then ease of removal is improved, but shape accuracy and stability worsen due to deterioration over time
Solution Approach 1:
The patent uses composite materials consisting of model material layers and support material layers. The model material maintains shape accuracy and prevents deterioration, while the support material provides ease of removal. This composite structure resolves the contradiction between ease of removal and shape accuracy by assigning different functional roles to each material component.
3Ease of manufacture
If model material and support material are ejected with equal density, then manufacturing simplicity is improved, but support structure strength and shape control worsen
Solution Approach 1:
The patent applies local quality by differentiating the density characteristics of model material and support material. The model material is ejected with higher density to provide structural strength, while the support material is ejected with lower density for ease of removal. This localized differentiation of material properties resolves the contradiction between manufacturing simplicity and support structure strength.
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 maintains the strength of the support structure and facilitates easy removal, preventing shape variation and deterioration, compared to using only support material, while ensuring precise shape accuracy and stability.
Implementation Method 1
a UV light source to cure the model material and the support material; a controller to control the inkjet type ejection heads and the UV light source
Data Source
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AI summary
A three dimension forming apparatus 10 includes a model material ejection unit 16 that ejects a model material, a support material ejection unit 20 that ejects a support material, and a controller 12 that controls the model material ejection unit 16 and the support material ejection unit 20 such that the model material and the support material are arranged as a support structure 42 in an arrangement pattern containing the model material and the support material, the support structure 42 supporting or protecting a three-dimensional structure 40 to be formed by the model material.