Interlocked Anchoring Base for 3D Printing Warping Control
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Solution Overview
Problem
Conventional three-dimensional object printing techniques face challenges with warping and difficulty in removing printed objects from the build platen without damaging them, as existing methods either introduce complexity and expense or provide insufficient resistance against warping.
Innovation Solution
An additive manufacturing system that forms a planar base with a layer of build material and interlocked anchoring portions using both build and support material, which adheres to the platen to prevent warping and facilitates easy removal by creating a stable, interlocked structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the object adheres to the build platen during printing, then warping is prevented, but removal of the object becomes difficult and may damage the object
Solution Approach 1:
The base layer is segmented into build material portions and support material portions, with the support material forming anchoring portions that provide strong adhesion for warping resistance while the build material portions can be selectively removed. This segmentation allows different regions of the base layer to serve different functions: support material for anchoring and build material for the object structure.
Solution Approach 2:
The support material is extracted and removed after printing completes, taking the anchoring function with it. The support material portions that formed the anchoring portions are removed, releasing the object from the build platen while the build material portions remain as part of the final object. This extraction resolves the contradiction by removing the adhesion mechanism after it has served its purpose.
2Ease of operation
If a base layer of support material is used to prevent direct adhesion, then object removal is facilitated, but sufficient resistance against warping is not provided
Solution Approach 1:
Different portions of the base layer have different qualities: support material portions provide strong adhesion for warping resistance, while build material portions provide structural integrity. The support material is specifically placed in anchoring portions where strong adhesion is needed, while build material is used where the object structure will be formed. This local differentiation resolves the contradiction by providing strong adhesion only where needed for warping resistance.
Solution Approach 2:
The base layer is a composite structure combining build material and support material in specific patterns. The support material portions form anchoring portions that provide strong adhesion to the build platen, while build material portions provide structural support. This composite approach allows the base layer to simultaneously provide warping resistance through support material adhesion and facilitate removal through selective support material removal after printing.
3Ease of operation
If heating elements are added to the build platen to facilitate removal, then object removal is enabled, but complexity, expense, and additional warping risks are introduced
Solution Approach 1:
The support material acts as a disposable, temporary structure that provides the necessary anchoring function during printing and then is removed. Rather than adding permanent, expensive heating elements to the build platen, the patent uses consumable support material that is ejected, forms anchoring portions, and is then removed after printing. This replaces a permanent complex solution with a temporary, simpler one.
Solution Approach 2:
The support material serves as an intermediary between the build platen and the object. It provides the adhesion needed for warping resistance during printing, then is removed to facilitate object removal. This intermediary approach avoids the need for complex heating elements by using a material-based solution that naturally provides and then releases the adhesion function.
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 system enables accurate and warp-resistant three-dimensional object printing with reduced risk of damage during removal, eliminating the need for expensive or complex build platens and minimizing additional processing steps.
Implementation Method 1
During the printing process, the build material and support material generally harden in response to cooling, curing, or a similar process.
Implementation Method 2
During the printing process, the build material and support material generally harden in response to cooling, curing, or a similar process.
Data Source
AI summary
A method of forming a base for supporting a three-dimensionally printed object includes operating at least one ejector of a three-dimensional object printer to form the base. At least one ejector is operated to eject build material to form a planar layer of build material on a platen, and to form a first plurality of anchoring portions on the planar layer. At least one ejector is operated to eject support material to form a plurality of second anchoring portions interlocked with the first anchoring portions so that the first and second anchoring portions form a planar anchoring layer, and to form a planar layer of support material on the anchoring layer that defines a planar base for supporting a three-dimensional object.