Base Sheet for 3D Printed Metal Objects
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Solution Overview
Problem
Current additive manufacturing techniques face challenges in securely adhering and separating printed metal objects from a base sheet during the printing process, especially when using metal injection molding materials, which can lead to deformation and integrity issues.
Innovation Solution
A method involving a base sheet that forms a cross-linked bond with the binder material of the printed object, allowing for secure adhesion during printing and easy separation post-printing, using materials like polypropylene or polyethylene, and securing the base sheet to a build plate through adhesives, vacuum, or magnets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the base sheet is securely adhered to the printed object during printing, then the object maintains integrity during the printing process, but the base sheet becomes difficult to separate from the object after printing
Solution Approach 1:
The patent changes the chemical parameters of the base sheet material to achieve selective bonding. The base sheet is made from a material that does not form strong bonds with the binder component under printing conditions, allowing easy separation after printing while maintaining object integrity during the printing process.
Solution Approach 2:
The base sheet acts as an intermediary element between the build plate and the printed object. It provides a temporary support surface during printing that can be easily removed afterward, facilitating the printing process without compromising the final object or creating separation difficulties.
2Strength
If the base sheet material forms a strong bond with the binder component, then the object adheres securely during printing, but the base sheet cannot be easily peeled from the object after printing
Solution Approach 1:
The patent modifies the material parameters of the base sheet by selecting a material with specific chemical properties that prevent strong bonding with the binder component. This parameter change ensures weak adhesion that allows easy peeling while still providing sufficient support during printing.
Solution Approach 2:
The base sheet material is selected to have different bonding characteristics at different stages: during printing, it provides adequate local support where needed, but the chemical composition ensures that no strong bonds form between the base sheet and binder component, enabling easy separation afterward.
3Ease of operation
If the base sheet is made thin for easy handling, then it can be easily manipulated and removed, but it may not provide sufficient support during the printing process
Solution Approach 1:
The patent changes the material parameters of the base sheet by selecting a material with optimized mechanical properties. The material is engineered to provide sufficient flexural strength and rigidity even at thin dimensions (0.1-3 mm), allowing the base sheet to maintain structural support during printing while remaining easy to handle and remove.
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 production of intact and deformation-free metal objects by ensuring the base sheet remains securely attached during printing and can be easily detached post-printing, facilitating debinding and sintering processes.
Implementation Method 1
The base sheet may be composed of a material that forms a cross-linked bond with a binder material of the object at the at least one contact point during the printing
Implementation Method 2
The base sheet may be coupled to a magnet, and the magnet may be applied to the build plate to form a magnetic bond securing the base sheet to the build plate
Implementation Method 3
The base sheet may be composed of a material that dissolves in response to exposure to the chemical solvent
Data Source
AI summary
A 3D printer includes a build plate providing a surface on which an object is printed. Prior to printing, a sheet is fixed to the surface of the build plate. The sheet is composed of a material that adheres to a binder component of the feedstock used to print the object. During printing, the first layer of the printed object forms a bond with the sheet, which secures the location of the first layer and resists movement of the object during printing. Following printing and the object gaining sufficient rigidity, the object and sheet can be removed together from the printer. The sheet may then be peeled from the object, and the object can undergo debinding and/or sintering to create a finished object.