3D Printing Base Layer Protrusions for Stress Distribution
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Solution Overview
Problem
Three-dimensional printing technologies face challenges in preventing deformation during the initial stages of printing due to mechanical and thermal stresses in the base layers of objects, leading to potential aberrations and structural issues in the final product.
Innovation Solution
The introduction of protrusions in the base layer, which are not present in the original model, to distribute stress and prevent deformation, with these protrusions being designed to be sacrificial and removable after printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the base layer is printed directly without modifications, then the printing process is simple and fast, but deformation occurs due to mechanical and thermal stresses
Solution Approach 1:
The patent applies preliminary action by adding protrusions to the base layer model before printing. These protrusions are pre-positioned to counteract the mechanical and thermal stresses that will occur during the printing process, preventing deformation before it happens. The protrusions are strategically placed at locations where stress concentration is expected to occur.
Solution Approach 2:
The patent applies local quality by modifying only specific regions of the base layer rather than the entire structure. The protrusions are added locally at critical stress points where needed, while other regions remain unchanged. This localized modification maintains overall structural integrity while addressing specific deformation problems.
2Manufacturing precision
If protrusions are added to the base layer to distribute stress, then deformation is reduced, but the base layer structure becomes more complex
Solution Approach 1:
The patent applies the discarding and recovering principle by designing the protrusions as sacrificial elements that are removed after printing. The protrusions serve their stress-distribution function during the printing process, then are discarded in a subsequent removal step. This allows the base layer to achieve dimensional accuracy during printing without permanent structural complexity in the final object.
3Manufacturing precision
If the base layer thickness is increased to reduce deformation, then stress distribution improves, but the overall object dimensions change
Solution Approach 1:
The patent applies local quality by adding protrusions only at specific critical locations in the base layer rather than uniformly increasing the entire base layer thickness. This localized approach distributes stress where needed while maintaining the overall dimensional specifications of the object, avoiding unnecessary changes to the final shape.
Data Source
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AI summary
A printed object includes a modification not present in the original model of the object. The modification is included in a base layer of the object.