3D Shaping Stage Groove Layout for Shrinkage-Resistant Adhesion
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Solution Overview
Problem
Existing three-dimensional shaping devices face challenges in maintaining the positional relationship between shaped objects and the shaping surface when using materials with high shrinkage rates, as gaps can form between protruding and recessed portions, leading to the protruding portions coming off and disrupting the shaping process.
Innovation Solution
A three-dimensional shaping device with a stage featuring grooves in specific configurations and a controlled material discharge mechanism that forms interlocking shaping lines and layers, ensuring precise positioning and adhesion through a series of controlled material deposition and movement steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shaping material having a large shrinkage rate is used to form protruding portions in recessed portions for preventing object movement, then the shaped object is less likely to move on the shaping surface, but gaps are formed between the protruding portion and the recessed portion, causing the protruding portion to come off and making it difficult to maintain the positional relationship between the shaped object and the stage
Solution Approach 1:
The underlayer is divided into multiple segments (first underlayer and second underlayer) with different groove patterns. The first underlayer has grooves in a first pattern while the second underlayer has grooves in a second pattern, creating a multi-scale interlocking structure that accommodates shrinkage while maintaining positional stability.
Solution Approach 2:
Different regions of the underlayer are given different groove patterns tailored to local requirements. The first underlayer and second underlayer have distinct groove configurations that optimize adhesion and shrinkage accommodation in different areas, preventing uniform gap formation while maintaining overall positional stability.
2Strength
If grooves are formed on the shaping surface to create interlocking protruding portions, then adhesion between the shaped object and stage is improved, but gaps form during material discharge causing the protruding portions to come off
Solution Approach 1:
The grooves are segmented into different patterns across the first and second underlayers. This segmentation creates a hierarchical interlocking structure where material can be discharged into grooves of one pattern while maintaining engagement with grooves of another pattern, preventing complete detachment while preserving adhesion strength.
Solution Approach 2:
The groove patterns are pre-configured in the stage before shaping begins. The first and second underlayers are formed with predetermined groove patterns that anticipate and accommodate the shrinkage behavior of the shaping material, ensuring that interlocking features remain engaged despite material contraction.
3Device complexity
If a single underlayer with uniform groove pattern is used, then the device complexity is reduced, but warpage and peeling occur when using materials with significant shrinkage
Solution Approach 1:
The underlayer structure is segmented into the first underlayer and second underlayer with different groove patterns. This segmentation allows each layer to independently accommodate shrinkage in different directions, reducing overall warpage while maintaining a relatively simple overall structure that can be efficiently manufactured.
Data Source
AI summary
A three-dimensional shaping device includes a stage having a shaping surface formed with a first, second, third, and fourth groove, a discharge unit configured to supply a shaping material to the shaping surface, a moving mechanism configured to relatively move the stage and the discharge unit, and a control unit configured to control the discharge unit and the moving mechanism. The control unit is configured to execute a control of forming a first shaping line in the first groove, a control of forming a second shaping line in the second groove, a control of forming a third shaping line in the third groove, a control of forming a fourth shaping line in the fourth groove, a control of forming a first floor layer that couples the first and second shaping lines, and a control of forming a second floor layer that couples the third and fourth shaping lines.