Auxiliary Structures Prevent 3D Part Detachment
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Solution Overview
Problem
In extrusion-based 3D printing, high-performance parts often detach from the build plate due to limited adhesion, leading to warpage and reduced production yield, especially when using materials that shrink significantly during cooling, which affects mechanical and aesthetic properties and increases production costs.
Innovation Solution
A method involving an intermediate structure with auxiliary structures printed around the 3D part to prevent detachment, where these auxiliary structures are designed to cover less than 50% of the surface and can be elongated, arranged at specific distances, and made from the same feedstock material as the part, helping to distribute stress and prevent warpage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple layers of modeling and support material are used to cover the carpet edges, then detachment is prevented, but printing time and costs increase significantly
Solution Approach 1:
The patent extracts only the essential function of preventing detachment by using a minimal auxiliary structure (single layer or limited layers) instead of multiple layers of support material. This reduces printing time while maintaining the reliability of preventing detachment during the printing process.
Solution Approach 2:
The patent applies partial action by using just enough support material to prevent detachment - specifically, a single layer or limited layers of auxiliary structure rather than excessive multiple layers. This achieves the necessary prevention function without the time penalty of over-engineering the support structure.
2Reliability
If multiple layers of modeling and support material are used to cover the carpet edges, then detachment is prevented, but production costs increase
Solution Approach 1:
The patent extracts only the essential function of preventing detachment by using a minimal auxiliary structure (single layer or limited layers) instead of multiple layers of support material. This reduces material consumption while maintaining the reliability of preventing detachment during the printing process.
Solution Approach 2:
The patent applies partial action by using just enough support material to prevent detachment - specifically, a single layer or limited layers of auxiliary structure rather than excessive multiple layers. This achieves the necessary prevention function without the material waste of over-engineering the support structure.
3Manufacturing precision
If a large print area is used to print the 3D part, then the part can be manufactured, but detachment and warpage occur due to limited adhesion
Solution Approach 1:
The patent introduces an intermediary auxiliary structure between the build plate and the main 3D part. This auxiliary structure acts as a mediator that provides enhanced adhesion to the build plate while supporting the large print area, preventing detachment and warpage without compromising the dimensional accuracy of the final part.
Solution Approach 2:
The patent segments the printing structure into two distinct parts: the main 3D part and the auxiliary support structure. This segmentation allows the auxiliary structure to be optimized specifically for adhesion and support functions, while the main part maintains its dimensional accuracy requirements.
4Quantity of substance
If auxiliary structures covering less than 50% of the surface are used, then material usage is reduced, but effectiveness in preventing detachment may be compromised
Solution Approach 1:
The patent applies local quality by concentrating the auxiliary structure at critical locations where detachment is most likely to occur, rather than uniformly covering the entire surface. This strategic placement of minimal auxiliary structure (covering less than 50% of the surface) provides maximum adhesion benefit while minimizing material usage.
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 enhances the production yield and reliability of high-performance 3D parts by preventing detachment and warpage, allowing for reduced material usage and costs, while maintaining mechanical and aesthetic properties suitable for critical applications.
Implementation Method 1
auxiliary structures that are designed to cover less than 50% of the surface and can be elongated, arranged at specific distances, and made from the same feedstock material as the part, helping to distribute stress and prevent warpage
Implementation Method 2
a printhead that is moveable in a 3D space with respect to a build surface while dispensing AM feedstock material
Implementation Method 3
a liquefying unit is used to melt the AM feedstock material and allow deposition via a nozzle on the build surface
Implementation Method 4
materials that shrink significantly during cooling
Data Source
AI summary
A method for preventing detachment of a 3D part from a build plate of a 3D printing system for fabricating the 3D part using an extrusion-based additive manufacturing process. The method includes providing an intermediate structure on top of the build plate, the intermediate structure having a surface that is larger than a print area required for printing the 3D part on top of the intermediate structure, and printing tracks of extruded feedstock material to fabricate the 3D part and at least one auxiliary structure that is arranged next to the 3D part for preventing detachment of the 3D part from the build plate. Herein, the at least one auxiliary structure covers less than 50% of the surface of the intermediate structure. A 3D printing system for performing the method, and a 3D part fabricated using an extrusion-based additive manufacturing process performed by said 3D printing system.