3D Shaping Method Groove Support for Sintering Distortion
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Solution Overview
Problem
Three-dimensional shaping methods using powdered materials often result in distortion of the final article due to shrinkage during the sintering process, as existing techniques fail to effectively manage the directional forces applied during this stage.
Innovation Solution
A method involving the formation of a molded body with projection portions that are supported by a structure with groove portions aligned to direct shrinkage, allowing the molded body to shrink without excessive force application, thereby minimizing distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a molded body is shrunk by heating during sintering, then the powder is sintered and the three-dimensional shaped article is formed, but the molded body distorts due to uncontrolled shrinkage forces
Solution Approach 1:
A support structure with groove portions is introduced as an intermediary between the molded body and the sintering process. The groove portions engage with projection portions on the molded body, acting as a mediator that controls and directs the shrinkage forces during sintering, preventing uncontrolled distortion while allowing the necessary dimensional reduction to occur.
Solution Approach 2:
The invention changes the physical parameters of the support structure, specifically providing groove portions with specific geometries (width, depth, orientation) that are optimized to control shrinkage. By adjusting these parameters, the support structure can accommodate and direct the shrinkage forces in desired directions while maintaining shape integrity in critical dimensions.
2Strength
If a recess portion is provided in the shaping plate to suppress peeling, then peeling is suppressed, but the molded body still distorts due to uncontrolled shrinkage direction
Solution Approach 1:
The support structure is segmented into multiple groove portions distributed across the shaping plate, each engaging with corresponding projection portions on the molded body. This segmentation allows different regions of the molded body to be controlled independently, managing shrinkage forces in a distributed manner rather than relying on a single recess portion, thereby preventing both peeling and distortion.
Solution Approach 2:
The invention transitions from a two-dimensional recess portion in the shaping plate to a three-dimensional support structure with groove portions that extend in specific directions. This dimensional enhancement allows the support structure to control shrinkage not only in preventing peeling but also in directing the shrinkage forces along predetermined paths, thereby controlling distortion in multiple dimensions.
3Manufacturing precision
If the molded body is supported during sintering, then shrinkage direction can be controlled, but the support structure adds complexity to the manufacturing process
Solution Approach 1:
The support structure with groove portions serves multiple functions simultaneously: it prevents peeling during sintering, controls the direction of shrinkage, and provides mechanical support for the molded body. By integrating these multiple functions into a single structure, the invention achieves precise shrinkage direction control without proportionally increasing device complexity, as the same structural elements perform multiple roles.
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 suppresses distortion and maintains the shape integrity of the three-dimensional article by specifying the direction of shrinkage, ensuring the molded body shrinks without applying excessive force, thus reducing strain and maintaining the article's shape.
Implementation Method 1
a molded body is shrunk with the progress of a sintering step
Implementation Method 2
a three-dimensional shaping method for shaping a three-dimensional shaped article by forming a molded body using a material containing a powder and a binder, and heating the molded body, thereby sintering the powder
Data Source
AI summary
A three-dimensional shaping method includes a molded body forming step of forming a molded body having a plurality of projection portions using a material containing a powder and a binder, a supporting step of supporting the molded body by a support having groove portions at positions configured to insert each of the projection portions in a state where the plurality of projection portions are inserted into the groove portions, and a sintering step of sintering the powder by heating the molded body in a state of being supported by the support, wherein the groove portion is extended from an insertion position of the projection portion in a specified direction that specifies a direction of shrinkage of the molded body by performing the sintering step.