3D Resin Wall-and-Fill Shaping for Stronger Layer Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Fused deposition modeling techniques face challenges in achieving high mechanical strength and precision in three-dimensionally shaped objects due to inter-layer gaps and reduced adhesion caused by surface polishing and electrical discharge treatments, which also increase resin consumption and shaping time.
Innovation Solution
A method involving the formation of a wall structure with a space open upward, allowing injection of fused thermoplastic resin into this space to create a filling portion, ensuring a gap-free interface and enhanced mechanical strength while maintaining precision, using a three-dimensional shaping apparatus with controlled ejection and movement mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If surface polishing and electrical discharge treatment are performed to reduce surface unevenness, then manufacturing precision is improved, but mechanical strength decreases and shaping time increases
Solution Approach 1:
The invention performs preliminary flattening of the deposited layer surface during the deposition process itself, before subsequent layers are added. By controlling the deposition parameters and using a flatting mechanism that operates immediately after each layer deposition, the surface is flattened while the resin is still warm and pliable, avoiding the need for post-deposition polishing that would cool and stiffen the material, thus preserving mechanical strength
Solution Approach 2:
The invention extracts and eliminates the separate polishing and electrical discharge treatment steps from the conventional process. By integrating surface flattening into the deposition process itself through controlled deposition parameters and in-process flattening mechanisms, the harmful post-treatment steps are removed, preventing adhesion degradation and reducing total shaping time
2Manufacturing precision
If surface polishing is performed to flatten the layer surface, then manufacturing precision is improved, but resin consumption increases and shaping time increases
Solution Approach 1:
The flattening action is performed preliminarily during the deposition process itself rather than as a separate post-treatment step. By flattening the surface while the layer is still warm and pliable immediately after deposition, the process eliminates the need for time-consuming separate polishing operations, thereby reducing total shaping time while maintaining surface flatness
Solution Approach 2:
The invention merges the flattening function with the deposition process. The flatting mechanism operates in conjunction with the deposition head, combining two functions (deposition and flattening) into a single integrated process step, eliminating the need for separate polishing equipment and operations, thus improving productivity
3Device complexity
If conventional layer-by-layer deposition is used, then device complexity is kept simple, but inter-layer gaps occur and mechanical strength is insufficient
Solution Approach 1:
The invention introduces a flatting mechanism as an intermediary component between the deposition head and the base stage. This mediator flattens the deposited layer surface immediately after deposition, creating a smooth interface for the next layer, thereby preventing inter-layer gaps and improving mechanical strength without requiring complex changes to the overall apparatus structure
Solution Approach 2:
The invention changes the temperature and viscosity parameters of the resin during deposition. By controlling the resin temperature to maintain optimal viscosity ranges, the resin flows more smoothly and fills gaps between layers more effectively, improving adhesion and mechanical strength while keeping the apparatus structure relatively simple
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
The method achieves a three-dimensionally shaped object with improved mechanical strength and precision, reducing inter-layer gaps and resin consumption, and shortening the shaping process by ensuring a secure bond between layers without the need for extensive surface treatment.
Implementation Method 1
a heating portion that heats and fuses the thermoplastic resin to a temperature of glass transition temperature Tg or higher
Implementation Method 2
an ejection nozzle that ejects the fused thermoplastic resin by applying pressure thereto
Implementation Method 3
a vibratory portion that vibrates the base stage
Data Source
AI summary
A three-dimensional shaping apparatus includes an ejection portion, a base stage, a movement portion, and a controller. The ejection portion configured to eject a fused thermoplastic resin. The movement portion configured to change relative positions of the ejection portion and the base stage. The controller configured to control the movement portion and the ejection portion such that a wall is formed by ejecting a fused thermoplastic resin from the ejection portion while relatively moving the ejection portion with respect to the base stage to provide a space surrounded by the wall in a horizontal direction and open in an upward direction, and such that a filling portion is formed by injecting a fused thermoplastic resin into the space from above.