3D Shaped Object Brim Support for Warping Suppression
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Solution Overview
Problem
Existing methods for manufacturing three-dimensional shaped objects fail to sufficiently suppress warping due to deformation of the brim, especially when the brim area is increased, as the brim itself deforms during the shaping process.
Innovation Solution
A method involving the formation of a release layer, a main body part, and a brim layer, where the brim layer includes a support structure part that contacts the main body part over multiple layers, using the same material for both layers to enhance adhesion and reduce warping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the area of the brim is increased to suppress warping, then the warping suppression effect is improved, but the brim itself deforms due to its own weight and material stress
Solution Approach 1:
The brim is divided into multiple independent brim layers stacked vertically, with each layer having a smaller area than the previous one. This segmentation reduces the weight and material stress on each individual brim layer, preventing deformation while collectively maintaining warping suppression through the stacked structure
Solution Approach 2:
The solution transitions from a single large horizontal brim structure to a multi-layer vertical stacked structure. By adding the vertical dimension and reducing horizontal area per layer, the design achieves both warping suppression and deformation prevention simultaneously
2Ease of manufacture
If the brim layer is separated from the main body part, then the release process is simplified, but the adhesion between brim layer and main body part may be insufficient
Solution Approach 1:
The brim structure is segmented into multiple stacked layers that are separated from the main body part, enabling simplified release while maintaining structural integrity through the layered configuration
Solution Approach 2:
The same material is used for both the main body part and the brim layers, ensuring sufficient adhesion strength between the separated components while allowing easy release of the brim layers after shaping
Data Source
AI summary
A method for manufacturing a three-dimensional shaped object includes: a first process of ejecting a first shaping material to shape a release layer on a stage; a second process of ejecting a second shaping material and stacking a shaped layer on the release layer to shape a main body part of a three-dimensional shaped object; and a third process of ejecting a third shaping material to shape a brim layer on the release layer, wherein the release layer and the brim layer are layers separated from the main body part shaped by the second process, and a corner part of the brim layer and an outline of the main body part come into contact with each other over a plurality of shaped layers.