Curved Build Platform for 3D Printing Separation
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Solution Overview
Problem
Existing three-dimensional rapid prototyping methods face challenges in separating newly solidified layers from a planar solidification substrate, leading to increased separation forces that can break the object and limit the build area, reducing the number and size of objects that can be manufactured.
Innovation Solution
A curved build platform that moves in multiple dimensions, allowing the solidified material to be separated along a line rather than an area, reducing separation forces and enabling larger objects to be built by maintaining a constant layer thickness and alignment with a linear solidification device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a planar solidification substrate is used with a large build area, then more objects can be manufactured simultaneously, but the separation force required to detach solidified layers becomes too great and breaks the objects
Solution Approach 1:
The patent divides the solidification substrate into multiple independent linear substrates arranged in an array. Each linear substrate handles a portion of the build area, allowing separation forces to be distributed across multiple independent separation lines rather than concentrated on a single large planar interface. This segmentation enables larger total build areas while maintaining manageable separation forces at each individual substrate.
Solution Approach 2:
The patent transitions from a two-dimensional planar substrate to a multi-dimensional array of linear substrates. By arranging substrates in multiple rows and columns and enabling movement in X, Y, and Z directions, the system creates a three-dimensional workspace that accommodates large build areas while maintaining linear separation interfaces. The build platform and substrates can move independently in multiple dimensions to optimize the separation process.
2Productivity
If the build area is increased to manufacture larger objects, then productivity improves, but the separation force required increases proportionally with the interface area
Solution Approach 1:
The solidification substrate is segmented into multiple linear substrates that can be independently moved and positioned. Each linear substrate creates a narrow separation interface, keeping separation forces at manageable levels regardless of the total build area. The array configuration allows large objects to be built by distributing the separation workload across multiple substrates.
Solution Approach 2:
The system employs dynamic movement capabilities where the build platform and linear substrates can move independently in X, Y, and Z directions. This dynamic positioning allows the system to optimize separation by moving substrates away from the build area after solidification, reducing the separation interface area and consequently the separation forces required, even for large build areas.
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 allows for the construction of larger three-dimensional objects without breaking, as the concentrated separation forces along a line reduce the risk of damage during the separation process, enabling more extensive and complex builds.
Implementation Method 1
solidification energy is supplied to a solidifiable material to solidify a layer of the solidifiable material
Data Source
AI summary
An apparatus and method for making a three-dimensional object from a solidifiable material using a linear solidification device is shown and described. Either a build platform or a solidification substrate has a curved surface, and each point on the curved surface traverses a trochoidal path during an object solidification operation. The curved surface allows the separation forces between the solidification substrate and the most recently solidified layer of material to be concentrated along a line instead of along a planar section which reduces the overall separation force and the likelihood of damaging a part.