Dynamic Support Surface for Curved-Bottom 3D Printing
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Solution Overview
Problem
Existing additive layer manufacturing (ALM) systems require disposable or removable support materials for fabricating 3D items with curved shapes, which are not reusable and inefficient for producing items with varying surface areas, especially when working with semi-solid materials like edible 3D foodstuff that need firm support during layer extrusion.
Innovation Solution
A dynamic support apparatus with a manipulable surface that adjusts its concavity from a first to a second position, allowing it to provide increased support for layers with larger surface areas, using a manipulating mechanism that can change the curvature of the surface in response to the weight of the printed item, eliminating the need for disposable supports and enabling the fabrication of curved-bottom 3D items without material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If disposable or removable support materials are used for fabricating 3D items with curved shapes, then the fabrication of curved shapes is enabled, but the support materials cannot be reused and generate waste
Solution Approach 1:
The support apparatus employs a dynamic surface that can change its curvature and shape during the fabrication process. The surface transitions between different concavity states to adapt to the evolving geometry of the printed item, eliminating the need for disposable supports. This dynamic adaptation allows the same support structure to serve multiple purposes throughout layer fabrication.
Solution Approach 2:
The support apparatus changes its physical parameters, specifically the curvature radius and surface area, by manipulating the dynamic surface between different positions. The surface area varies from a first surface area to a second surface area that is larger, enabling the support to accommodate layers with increasing surface areas while maintaining curved shape fabrication capability.
2Shape
If layers are printed with larger surface areas than the layer beneath them, then more complex 3D shapes can be fabricated, but material spillage occurs from the edges
Solution Approach 1:
The dynamic surface adjusts its curvature in real-time during layer fabrication. When a layer with larger surface area is being printed, the surface increases its concavity to provide lateral support along the edges, preventing material spillage while still allowing the fabrication of complex shapes with overhanging features.
Solution Approach 2:
The support apparatus provides localized support where needed by selectively increasing concavity at specific regions of the dynamic surface. This allows edges of layers with larger surface areas to be supported precisely where material spillage would occur, while maintaining the overall complex shape geometry.
3Adaptability or versatility
If semi-solid materials are used for 3D foodstuff printing, then edible printed items can be produced, but firm support is required during extrusion
Solution Approach 1:
The dynamic surface provides adjustable firmness and support characteristics tailored to the specific layer being fabricated. When extruding semi-solid edible materials, the surface maintains appropriate rigidity and contact area to support the material weight and prevent deformation, while still allowing the material to be deposited and shaped.
Solution Approach 2:
The support apparatus modifies its surface parameters such as surface area and curvature to match the requirements of semi-solid material extrusion. The surface area increases to distribute the weight of extruded edible materials, and the curvature adjusts to provide optimal contact and support during the extrusion process.
4Shape
If disposable support materials are used for each fabrication, then support for curved shapes is provided, but the support apparatus cannot be reused across different items
Solution Approach 1:
The dynamic surface can be reconfigured and manipulated between different positions and curvature states to support various curved shape requirements for different items. This reusability through dynamic reconfiguration eliminates the need for disposable supports while maintaining the ability to fabricate diverse curved geometries across multiple fabrication cycles.
Solution Approach 2:
The support apparatus is designed as a universal platform that can accommodate different fabrication requirements through its dynamic surface manipulation capabilities. The same apparatus can support various curved shapes, different layer configurations, and multiple item types by adjusting the surface position and curvature, making it reusable across different fabrication tasks.
Data Source
AI summary
A support apparatus for use in conjunction with an ALM system having a printing head being movable with respect to the support apparatus. The support apparatus a dynamic surface configured to support a printed 3D item thereon during fabrication thereof by the printing head, the dynamic surface being manipulable between a first position, at which the dynamic surface has a first concavity with respect to the printing head, and a second position, at which the dynamic surface has a second concavity with respect to the printing head, the second concavity being greater than the first concavity; and a manipulating mechanism operable to induce manipulation the dynamic surface at least from the first position to the second position.