3D Printed Sacrificial Supports for Curing Airflow Deformation
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Solution Overview
Problem
Powder-based 3D printing techniques face issues with deformation of printed structures during the curing process due to airflow-induced compaction of underlying powder, which can lead to permanent deformation before the binder agent is fully cured.
Innovation Solution
Generate additional sacrificial object models or parts in specific locations within the build bed to provide mechanical support to the intended object, using a pre-printing analysis to determine deformation-prone areas and applying sacrificial parts to mitigate airflow effects during the curing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If airflow is applied during the curing process to remove binder agent solvent vapour, then the curing efficiency is improved, but deformation of the printed structure occurs due to compaction of underlying powder
Solution Approach 1:
The patent applies preliminary action by generating support structures (sacrificial parts or additional printed structures) before the curing process begins. These support structures are positioned in the build bed to counteract the compaction forces that will be applied by the airflow during curing, thereby preventing deformation of the printed structure while maintaining high curing efficiency
Solution Approach 2:
The patent introduces intermediary support structures that act as mediators between the airflow and the printed structure. These support structures absorb the compaction forces from the airflow and transfer them to the build bed, protecting the printed structure from deformation while allowing the airflow to continue removing solvent vapour efficiently
2Manufacturing precision
If additional sacrificial parts are generated in the build bed, then mechanical support is provided to prevent deformation, but the complexity of the printing process increases
Solution Approach 1:
The patent employs sacrificial parts that are intentionally designed to be temporary and disposable. These parts are printed alongside the main structure to provide support during curing, then removed after serving their protective function. This approach maintains manufacturing precision while managing process complexity through the use of simple, removable support elements
Solution Approach 2:
The patent applies the discarding principle by generating support structures that are removed after the curing process. These sacrificial parts are discarded after providing their temporary mechanical support function, allowing the build bed to be reused for subsequent printing operations without permanent modification, thus balancing precision requirements with process simplicity
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
Reduces or prevents deformation of 3D printed objects by providing additional mechanical support, ensuring the integrity of the final product without modifying airflow characteristics.
Implementation Method 1
The thermally curable binder agent is thermally cured in a curing process to form a sufficiently strong green part
Implementation Method 2
During the curing process, solvents in the binder agent are extracted from the build bed using a gas flow
Implementation Method 3
the curing gas flow may cause compaction of the underlying powder and hence this may cause the printed structure to deform
Data Source
AI summary
According to one aspect, there is provided a method of automatically creating sacrificial parts to be printed in the three-dimensional printer. The method comprises obtaining object model data relating to a three-dimensional object to be printed in a build chamber by a three-dimensional printer. The method determines whether the object will likely be deformed during a curing process of contents of the build chamber, wherein the curing process comprises heating of the contents of the build chamber and generating a gas flow. If the determination is affirmative, the method includes generating updated object model data including additional object to be printed in proximity to the object, the additional object to prevent deformation of the object due to the gas flow applied during the curing process.