3D Printing Wall Support Fluid Injection
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Solution Overview
Problem
Conventional additive manufacturing methods require supports for isolated portions of three-dimensional objects, which are laborious to remove and often necessitate precise positioning, and either use excessive material or require a vat for support material reuse.
Innovation Solution
A method involving a belt-shaped intermediate transfer member with a transport mechanism to form layers with a surrounding wall for support, using a fluid support material injected between the object and the wall, allowing for reduced material usage and eliminating the need for precise support positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If support material is applied to the entire surface and reused, then material efficiency is improved, but the apparatus requires a large vat and precise positioning is needed
Solution Approach 1:
The patent applies support material only in the specific regions where it is needed (between the wall and the object being formed) rather than across the entire surface. This localized application reduces the volume of support material required and eliminates the need for a large vat, while also reducing positioning precision requirements since material is supplied only where needed.
Solution Approach 2:
The patent introduces a wall structure that creates a three-dimensional confined space, changing the geometry from a two-dimensional surface application to a three-dimensional volumetric containment. This allows support material to be supplied in a controlled manner within the confined space, reducing overall material requirements while maintaining support functionality.
2Loss of substance
If support material is applied only where needed, then material consumption is reduced, but support material cannot be reused and precise positioning is required
Solution Approach 1:
The patent forms a wall structure beforehand that defines the confined space where support material will be supplied. This preliminary action of creating the wall eliminates the need for precise positioning during support material supply, as the wall itself provides the spatial boundaries. The support material is then supplied in advance within this pre-defined space.
Solution Approach 2:
The wall acts as an intermediary structure that mediates between the support material and the object being formed. It provides a confined space that contains the support material, eliminating the need for precise positioning while still allowing localized application. The wall serves as the intermediate element that enables both material efficiency and ease of manufacture.
3Ease of operation
If conventional additive manufacturing stacks layers with supports, then isolated portions can be formed, but support removal is laborious and material usage is excessive
Solution Approach 1:
The patent extracts the support function from the traditional layer-stacking process by introducing a separate wall structure. The wall provides the support function externally, allowing the object being formed to be manufactured without incorporating support material within its layers. This separation makes support removal simpler while reducing overall material consumption.
Solution Approach 2:
The patent segments the manufacturing process into two distinct functional elements: the object being formed and the wall providing support. This segmentation allows the support function to be independently optimized and removed separately from the object, reducing labor for support removal and minimizing material consumption since support material is confined to the space between the wall and object.
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 enables efficient manufacturing with reduced material consumption and simplified support removal, facilitating the creation of complex shapes without the need for precise support positioning, while allowing for high precision and reusability of support materials.
Implementation Method 1
supplying a fluid material between the wall and the object being formed as a support material for supporting the object
Data Source
AI summary
Building is performed with a relatively small amount of material. Provided is a method for manufacturing a three-dimensional object. This method includes the steps of stacking a plurality of layers for forming an object; building a wall surrounding the object being formed; and supplying a material between the wall and the object being formed as a support material for supporting the object being formed.