3D Printed Support Layer Segmentation for Delicate Part Removal
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Solution Overview
Problem
Existing three-dimensional shaping devices using inkjet layered methods face challenges in handling delicate parts due to the fragility of support layers and the time-consuming dissolution process for large objects, which can result in damage or prolonged processing times.
Innovation Solution
A three-dimensional shaping device that incorporates a support layer with a dissolution removal target region and a non-dissolution removal target region, where the boundary is indicated by a different material region, allowing for physical removal of the non-dissolution target region without damaging the object and facilitating quicker dissolution of the support layer using water.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the support layer is removed by washing with water, then the support layer can be completely removed, but it takes a lot of time for large objects
Solution Approach 1:
The support layer is divided into two distinct regions: a dissolution removal target region that dissolves in water and a non-dissolution removal target region that is removed mechanically. This segmentation allows different removal methods to be applied to different parts of the support layer, enabling rapid mechanical removal of the non-dissolution region while the dissolution region is quickly removed by water washing, significantly reducing total processing time compared to complete water washing of the entire support layer
Solution Approach 2:
Different regions of the support layer are given different properties: the dissolution removal target region is designed to be water-soluble while the non-dissolution removal target region is designed to be mechanically removable. This local differentiation of material properties allows optimized removal strategies for each region, achieving fast overall removal without compromising complete support layer elimination
2Productivity
If the support layer is roughly removed with a technique, then most of the support layer can be removed quickly, but excessive force may damage delicate parts of the object
Solution Approach 1:
The dissolution removal target region is positioned between the delicate parts and the non-dissolution removal target region, acting as a protective buffer. During mechanical removal, this dissolution region absorbs and distributes applied forces, preventing excessive stress from reaching the delicate parts. The dissolution region serves as a preliminary protective action that safeguards delicate structures during the mechanical removal process
Solution Approach 2:
The dissolution removal target region functions as an intermediary layer between the mechanical removal zone and the delicate object parts. It mediates the force transmission during rough removal, allowing mechanical forces to be applied to remove the non-dissolution region while the dissolution region protects the delicate parts from damage. After mechanical removal, water washing completes the process by dissolving the intermediary dissolution region without requiring force application to the delicate parts
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 enables the safe and efficient removal of support layers from delicate objects, preventing excessive force application and reducing processing time by visually distinguishing the regions for targeted removal.
Implementation Method 1
the support material is a material that dissolves in a predetermined liquid... the dissolution removal target region being a region to be removed by dissolving in the predetermined liquid
Data Source
AI summary
In a three-dimensional shaping device, a support layer includes a dissolution removal target region removed by dissolving in the predetermined liquid and formed at a periphery of at least one part of the three-dimensional shaped object, and a non-dissolution removal target region removed through a method other than dissolution by the predetermined liquid and formed at a periphery of at least one part of the dissolution removal target region. At least one part of the support layer other than the dissolution removal target region is a different material region which is a region formed using a material different from the dissolution removal target region, and is formed at a position of at least one part of the periphery of the dissolution removal target region to indicate a position of a boundary between the dissolution removal target region and the non-dissolution removal target region.