3D Shaping Device Layer Adhesion and Surface Flatness
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Solution Overview
Problem
In three-dimensional shaping processes, the stacking of new layers on cut layers often results in distortion due to shrinkage stress, leading to surface steps and irregularities in the shaped object.
Innovation Solution
A method and device that involve cutting tools to shape and stack materials in a manner where each portion's length is shorter than the tool's cuttable length, with specific steps to manage shrinkage stress by heating and cutting in alternating directions, reducing the likelihood of surface steps and improving adhesion between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a new layer is stacked on a cut layer, then the three-dimensional shaped object can be formed by repeating shaping and cutting, but the cut layer is distorted due to shrinkage stress of the new layer, causing steps on the surface
Solution Approach 1:
The patent applies preliminary action by heating the cut layer before stacking the new layer. This pre-heating treatment prepares the cut layer in advance to reduce shrinkage stress distortion when the new layer is stacked, preventing surface steps from forming during the repeating shaping and cutting process
Solution Approach 2:
The patent changes the temperature parameter of the cut layer by applying heat treatment. This parameter change reduces the shrinkage stress of the new layer when it solidifies on the heated cut layer, thereby preventing distortion and maintaining surface flatness during repeated shaping and cutting operations
2Ease of manufacture
If the shaping material is stacked to form layers, then the three-dimensional object can be built up layer by layer, but shrinkage stress causes distortion and surface irregularities
Solution Approach 1:
The patent changes the temperature parameter of the previously stacked layer by applying heat. This parameter change reduces the shrinkage stress that occurs when the new layer solidifies, preventing distortion and maintaining good surface quality throughout the layer-by-layer manufacturing process
Solution Approach 2:
The patent converts the harmful shrinkage stress into a beneficial effect by heating the underlying layer. The heat treatment causes the underlying layer to expand slightly or become more compliant, which compensates for the shrinkage of the new layer, thereby transforming the potential harm into a benefit that maintains surface quality
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 reduces shrinkage stress and surface steps, enhancing the mechanical strength and surface quality of the shaped object by ensuring each layer is properly aligned and adhered, while preventing interference between cutting tools and the stage.
Implementation Method 1
a first portion shaping step of stacking a shaping material to shape a first portion
Implementation Method 2
the cut layer is distorted due to a shrinkage stress of the new layer
Data Source
AI summary
A method of manufacturing a three-dimensional shaped object, which is a method of shaping a three-dimensional shaped object using a cutting tool configured to cut a first length in a cutting direction, includes: a first portion shaping step of stacking a shaping material to shape a first portion having a length in the cutting direction shorter than the first length; a first portion cutting step of cutting the first portion in the cutting direction by the cutting tool; and a second portion shaping step of stacking the shaping material to couple to a first end surface of the first portion in a direction opposite to the cutting direction, and to shape a second portion having a length in the cutting direction shorter than that of the first portion.