Additive Manufacturing Base Plate Thermal Expansion Matching
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Solution Overview
Problem
Three-dimensional molded objects experience deformation and damage due to volumetric changes during heat treatment, resulting from differing thermal expansion characteristics between the solidified body and the base plate, leading to degradation of form accuracy and potential cracking.
Innovation Solution
A manufacturing method where the base plate and solidified body undergo heat treatment with matching thermal expansion characteristics, ensuring the base plate expands when the solidified body expands and shrinks when the solidified body shrinks, thereby minimizing dimensional differences and preventing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the base plate and solidified body are made of different materials, then the base plate can be reused and manufacturing cost is reduced, but volumetric change difference during heat treatment causes deformation and cracks
Solution Approach 1:
The invention changes the material parameter of the base plate to match the heat treatment characteristics of the solidified body. By selecting a base plate material with similar thermal expansion and phase transformation properties, the volumetric change difference during heat treatment is minimized, preventing deformation and cracks while maintaining base plate reusability.
Solution Approach 2:
The invention applies homogeneity by using the same or similar material for both the base plate and solidified body. This material homogeneity ensures that both components undergo similar volumetric changes during heat treatment, eliminating differential expansion/contraction that causes deformation and cracking.
2Reliability
If the base plate is made of the same material as the solidified body, then heat treatment compatibility is improved, but material waste increases and manufacturing cost rises
Solution Approach 1:
The invention changes the material parameter selection criteria to prioritize heat treatment compatibility over complete material identity. The base plate material is selected to have matching thermal and phase transformation characteristics with the solidified body, ensuring reliable heat treatment performance while allowing for material differentiation to reduce waste.
3Strength
If heat treatment is performed to improve strength and hardness, then the mechanical properties are enhanced, but volumetric change difference causes deformation and cracks
Solution Approach 1:
The invention changes the material parameters of the base plate to match those of the solidified body, specifically targeting thermal expansion coefficients and phase transformation characteristics. This parameter matching ensures that both components undergo identical volumetric changes during heat treatment, enabling strength and hardness improvement without deformation or cracking.
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 suppresses deformation and damage to the three-dimensional molded object by ensuring the base plate and solidified body change dimensions in a similar manner during heat treatment, maintaining form accuracy and preventing cracks.
Implementation Method 1
each of the solidified body and the base plate individually undergoes volumetric change due to transformation in structure derived from its specific heat treatment characteristics
Implementation Method 2
A predetermined portion of the material layer is irradiated with a laser beam or an electron beam to sinter or melt the material powder at the irradiated portion
Implementation Method 3
A predetermined portion of the material layer is irradiated with a laser beam or an electron beam to sinter or melt the material powder at the irradiated portion
Implementation Method 4
A predetermined portion of the material layer is irradiated with a laser beam or an electron beam to sinter or melt the material powder at the irradiated portion
Data Source
AI summary
A manufacturing method for a three-dimensional molded object includes repeating formation of a material layer and formation of a solidified layer, the material layer being formed by spreading a metal material on a base plate and the solidified layer being formed by irradiating the material layer with a laser beam or an electron beam, thereby molding a solidified body which is a laminated solidified layer on the base plate; and subjecting the base plate and the solidified body after molding to a heat treatment.