Flexible Element Peeling Mechanism for 3D Printing Damage Reduction

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Solution Overview

Problem

Existing methods for fabricating three-dimensional objects, such as rapid prototyping, face challenges in efficiently forming sections without damaging the object due to high separation forces required, especially when dealing with delicate materials and overhanging features, and often result in material wastage and contamination.

Innovation Solution

A method and apparatus that utilize a flexible element with a material receiving surface, where a shaping member contacts and tilts to induce peeling separation, reducing forces exerted on the object and allowing for the use of a modest volume of material, thereby minimizing waste and preventing object damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional rapid prototyping methods are used to form sections, then objects can be fabricated layer by layer, but high separation forces are required that may damage delicate objects

Engineering Contradiction:

Improvefabrication capabilityVSAvoiddamage to delicate objects

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The flexible element is made dynamically flexible rather than rigid, allowing it to bend and peel away from the object during separation. This dynamic flexibility enables the element to accommodate the object's geometry without requiring high separation forces, thereby preventing damage to delicate features while maintaining productive layer-by-layer fabrication.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The material properties of the flexible element are specifically selected to provide appropriate flexibility and peeling characteristics. By changing the physical parameters of the flexible element (such as its elasticity and surface properties), the separation process can proceed with minimal force, resolving the contradiction between maintaining fabrication capability and preventing object damage.

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If a rigid support structure is used to hold the flexible element, then the element can maintain its shape, but the structure becomes complex and requires precise alignment

Engineering Contradiction:

Improveshape stability of flexible elementVSAvoidalignment and calibration requirements

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The flexible element serves its own support function through its inherent flexibility and ability to conform to the object's shape. Rather than requiring an external rigid support structure with complex alignment requirements, the element self-adjusts to maintain appropriate positioning and shape during the fabrication process, thereby reducing device complexity while preserving shape stability.

Inventive Principle:

Principle #25Self-service

3Quantity of substance

If a large volume of material is used to form sections, then complete coverage is achieved, but material wastage and contamination increase

Engineering Contradiction:

Improvematerial coverageVSAvoidmaterial wastage

Core Design Contradiction:

Quantity of substanceVSLoss of substance

Solution Approach 1:

The flexible element functions as a thin film that can be precisely positioned and conform to the object's surface. This thin-film approach provides complete coverage of the material layer while minimizing the overall volume of material required, thereby reducing both material wastage and contamination risks while maintaining adequate coverage for section formation.

Inventive Principle:

Principle #30Flexible shells and thin films

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

The solution enables the fabrication of complex objects with reduced risk of damage and material wastage, allowing for the creation of delicate features and overhanging structures with fewer supporting scaffolds, while maintaining the desired geometry and reducing the need for precise alignment and calibration.

Implementation Method 1

A layer of material is solidified in the shape of a section through the object

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Implementation Method 2

Once the surface that receives the shaping member is exposed to atmosphere, the flexible element may distort freely which in turn facilitates peeling of the section from the flexible element

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11511482B2Apparatus and method for making an object

Publication Date: 2022.11.29 ZYDEX

AI summary

A method for making an object and an apparatus for making the object in accordance with the method is disclosed. A section of the object is formed by irradiating a layer of material with a radiation, the layer of material being disposed on a material receiving surface of a flexible element shaped by a shaping member contacting the flexible element. The radiation passes through the member and the flexible element. The member is tilted to induce a peeling separation of the member from the element.