3D Printed Cavity Top Surface with Inclined Angles
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Solution Overview
Problem
When forming three-dimensional shaped objects with cavities without support materials, the upper portions above the cavities can deform due to gravity, leading to structural integrity issues.
Innovation Solution
A method involving the stacking of layers with overlapping and non-overlapping portions, where the non-overlapping portions form a top surface with intersecting inclined surfaces, with a rising angle of 35° or more and less than 90°, to prevent deformation and support the cavity structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a three-dimensional shaped object having a cavity is formed without using the support material, then the manufacturing complexity is reduced and the ease of manufacture is improved, but the portion located above the cavity may be deformed by gravity, causing the structural integrity to deteriorate
Solution Approach 1:
The patent applies preliminary action by forming inclined surfaces with a rising angle of 35° or more and less than 90° in the layers constituting the cavity top surface before final object formation. This preliminary structural preparation prevents deformation by gravity during subsequent manufacturing steps, allowing cavity formation without support materials while maintaining structural integrity.
2Loss of substance
If a three-dimensional shaped object having a cavity is formed without using the support material, then the quantity of material used is reduced and loss of substance is minimized, but the portion located above the cavity may be deformed by gravity, causing manufacturing precision to deteriorate
Solution Approach 1:
The patent forms inclined surfaces with a rising angle of 35° or more and less than 90° in the layers before completing the object formation. This preliminary structural preparation prevents deformation by gravity during subsequent steps, maintaining manufacturing precision while forming cavities without support materials, thereby reducing material loss.
3Reliability
If layers are stacked with non-overlapping portions to form a top surface with intersecting inclined surfaces, then the rising angle of 35° or more and less than 90° prevents deformation by gravity, but the stacking process becomes more complex, increasing device complexity
Solution Approach 1:
The patent segments the layer stacking process into overlapping portions and non-overlapping portions, where non-overlapping portions form inclined surfaces with a rising angle of 35° or more and less than 90°. This segmentation creates self-supporting structures that prevent deformation by gravity while maintaining relatively simple manufacturing processes.
4Reliability
If the rising angle of inclined surfaces is set to 35° or more and less than 90°, then deformation by gravity is prevented and structural integrity is improved, but the manufacturing process requires precise angle control, increasing measurement precision requirements
Solution Approach 1:
The patent specifies a rising angle parameter of 35° or more and less than 90° for the inclined surfaces formed by non-overlapping portions. This parameter change creates an optimal angle range that prevents deformation by gravity while being feasible for standard manufacturing processes, balancing structural integrity with manufacturing practicality.
Data Source
AI summary
A method for manufacturing a three-dimensional shaped object includes: a first step of shaping a shaped object having a cavity by stacking a plurality of layers by discharging a shaping material toward a stage, in which the first step includes a second step of performing stacking such that each of the layers includes an overlapping portion in contact with a layer immediately below in a stacking direction and a non-overlapping portion not overlapping the layer immediately below and forming a space in the stacking direction, a top surface having two intersecting inclined surfaces is formed in an upper portion of the cavity by the non-overlapping portion, and a rising angle of each of the two inclined surfaces from a surface parallel to the stage is 35° or more and less than 90°.