3D Metal Ceramic Part Support Removal via Segmented Resin
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Solution Overview
Problem
Existing methods for manufacturing three-dimensional shaped objects with complex structures often face challenges in removing supports, as the shape complexity prevents the support from being easily removed, leading to incomplete or deformed structures.
Innovation Solution
A method involving a structure shaping step with metal or ceramic powder and a binder, followed by a support shaping step using a resin-based support material, and a degreasing step to remove the support and binder, allowing for the precise formation and removal of supports even in complex structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a support structure is used to manufacture complex three-dimensional shaped objects, then the structural integrity during manufacturing is improved, but the support cannot be removed after shaping
Solution Approach 1:
The support structure is divided into multiple detachable segments rather than a single continuous structure. This segmentation allows individual segments to be removed sequentially after the main structure is formed, solving the problem of unable to remove continuous supports from complex geometries while maintaining structural integrity during the shaping process
Solution Approach 2:
The support material is selectively extracted or removed from specific regions after the main structure is formed. This extraction process allows the support to fulfill its temporary function during manufacturing and then be completely removed, enabling complex geometries that would otherwise be impossible to produce
2Adaptability or versatility
If the structure shape is made complex, then the design versatility is improved, but the support removal becomes difficult or impossible
Solution Approach 1:
By segmenting the support into modular components, the invention enables removal of supports even when the main structure has complex geometries. The segmented supports can be accessed and removed from various directions without compromising the integrity of the complex structure
Solution Approach 2:
The support structure is designed with preliminary considerations for future removal, incorporating detachable features and access pathways before the main structure is fully formed. This preliminary design enables subsequent removal operations even for complex geometries that would otherwise trap the supports
3Productivity
If the support material is not degreased, then the manufacturing process is simpler, but the final object precision and quality deteriorate
Solution Approach 1:
The degreasing process utilizes parameter changes such as temperature, solvent concentration, or processing time to selectively remove organic materials from the support structure. By optimizing these parameters, the process efficiently removes contaminants to achieve high precision while maintaining reasonable manufacturing efficiency
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
Enables the successful shaping and removal of supports in complex structures, ensuring high precision and rigidity of the final three-dimensional object by degreasing the support material, thereby overcoming the challenge of support removal in complex geometries.
Implementation Method 1
supplying a binder to a region corresponding to a structure of the three-dimensional shaped object to be shaped in the shaping material
Implementation Method 2
a degreasing step of degreasing the support and the binder
Data Source
AI summary
A method for manufacturing a three-dimensional shaped object includes a structure shaping step of supplying a shaping material including metal powder or ceramic powder, and supplying a binder to a region corresponding to a structure S of the three-dimensional shaped object to be shaped in the shaping material (step S140), a support shaping step of shaping, with a support material including a resin, a support T supporting the structure S (step S130), and a degreasing step of degreasing the support T and the binder, the support T being in a state of supporting the structure S (step S200).