Duplex 3D Printing Deformation Control
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Solution Overview
Problem
Existing three-dimensional printing methods face challenges in maintaining the intended shape of structures due to deformations caused by capillary effects, gravitational forces, and material shrinkage, which hinder the accurate duplex printing of complex shapes.
Innovation Solution
A method involving the use of a deformation-control substructure that includes a carrier substructure and an anti-capillarity extension to prevent capillary effects and sagging, combined with partial curing and surface treatment to enhance bonding, allows for precise control over pre-structure deformations and smooth surface formation through gravitational smoothening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the first pre-structure is arranged directly on the support structure without additional control mechanisms, then the printing process is simple, but capillary effects cause the pre-structure to stick to the support structure and deform
Solution Approach 1:
A deformation-control substructure is introduced as an intermediary between the first pre-structure and the support structure. This substructure includes a carrier portion and a deformation-control portion that prevents capillary effects from causing adhesion and deformation, while maintaining the simplicity of the overall printing process.
Solution Approach 2:
The support structure is segmented into distinct functional portions: a carrier substructure for holding the pre-structure and a deformation-control substructure for preventing capillary-induced deformation. This segmentation allows each portion to perform its specific function independently, resolving the contradiction between simplicity and precision.
2Device complexity
If the first pre-structure is supported only at its base, then the support structure is simple, but gravitational forces cause sagging and deformation of the pre-structure
Solution Approach 1:
The deformation-control portion of the support structure acts as an intermediary that distributes gravitational forces evenly across the pre-structure. This prevents sagging and maintains vertical profile accuracy without requiring complex active control mechanisms.
Solution Approach 2:
The deformation-control substructure provides counter-support forces that balance the gravitational forces acting on the pre-structure. By distributing these counter-forces through its design, it prevents sagging while keeping the support structure relatively simple.
3Productivity
If droplets are deposited quickly to increase printing speed, then productivity is improved, but capillary effects have more time to cause deformation before the material sets
Solution Approach 1:
The deformation-control substructure is prepared in advance to counteract capillary effects before they can cause significant deformation. This preliminary anti-action allows faster droplet deposition while maintaining shape accuracy, as the control mechanism is already in place to prevent capillary-induced deformation.
4Ease of manufacture
If the printing material is allowed to shrink naturally, then the material processing is simple, but the pre-structure deforms from its intended shape
Solution Approach 1:
The deformation-control substructure serves as an intermediary that constrains the printing material during shrinkage, preventing deformation while allowing the material to process naturally. This maintains shape fidelity without requiring complex active control of the material shrinkage process.
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 enables the accurate duplex printing of three-dimensional structures with smooth surfaces and precise control over deformations, preventing unwanted adhesion to the support structure and maintaining the intended shape, even for complex geometries and optical components.
Implementation Method 1
printing a three-dimensional structure is carried out by depositing droplets of printing ink side by side and one above the other in several consecutive depositing steps
Implementation Method 2
the droplets deposited in the first and second printing step smear under the influence of gravity, thus smoothing the printed surfaces
Implementation Method 3
capillary effects draw parts of the first and/or second pre-structure in a gap between the first pre-structure and the support structure after arrangement of the first pre-structure on the support structure
Data Source
Figure 1~4
Figure 5~8
AI summary
A method for duplex printing a three-dimensional structure by depositing droplets of printing ink at least partially side by side and one above the other, comprising the following steps: depositing droplets of printing ink in a first printing step in order to build up an intermediate first pre-structure (14), depositing droplets of printing ink in a second printing step in order to build up an intermediate second pre-structure on at least one side of the first pre-structure (14), rotating the first pre-structure (14) and arranging the first pre-structure (14) on a support structure (2) in a rearrangement step between the first and the second printing step, characterized in that an extension (6) of the first pre-structure (14) is arranged on a carrier substructure (3) of the support structure (2) and a main body of the first pre-structure (14) is arranged on an deformation-control substructure (4) of the support structure (2). The present description further relates to a duplex printed three-dimensional structure as well as a duplex printer.