Laminated Multi-Material Separation Layer for Additive Fabrication
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive fabrication techniques face challenges in separating parts from surfaces without applying excessive force, which can cause deformation or mechanical failure, and conventional separation layers like PDMS are incompatible with certain photopolymers, leading to undesirable reactions and reduced mechanical or optical properties.
Innovation Solution
A laminated multi-material separation layer is used, comprising a first material with elastic properties and a barrier layer that is impermeable to the photopolymer, allowing for reduced adhesion forces and increased oxygen permeability to inhibit curing, while being compatible with a wide range of photopolymer substances, thus minimizing the force required for separation and maintaining the integrity of the part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional separation layers like PDMS are used, then separation can be achieved, but the separation layer is incompatible with certain photopolymers leading to degradation and reduced mechanical or optical properties
Solution Approach 1:
The separation layer is divided into multiple functional layers: a first layer providing elastic properties for separation, and a second barrier layer providing chemical compatibility and oxygen permeability. This segmentation allows each layer to perform its specific function without interfering with the photopolymer, resolving the compatibility issue while maintaining separation capability.
Solution Approach 2:
The invention uses a composite structure combining materials with different properties - an elastic material for separation functionality and a barrier material for chemical compatibility and controlled oxygen permeability. This composite approach allows the separation layer to work with various photopolymers without degradation, maintaining both reliability and mechanical/optical properties.
2Ease of operation
If excessive force is applied to separate parts from surfaces, then separation can be achieved, but deformation or mechanical failure of the part occurs
Solution Approach 1:
The first layer of the separation layer is designed with specific elastic properties (Shore hardness 10-80) that allow it to deform and release adhesion forces during separation. This parameter optimization enables separation to occur with minimal force, preventing part deformation or mechanical failure while maintaining ease of operation.
3Reliability
If the separation layer has high oxygen permeability to inhibit curing, then separation is facilitated, but the separation layer material must be compatible with a wide range of photopolymer substances
Solution Approach 1:
The separation layer is segmented into two functional layers: the first layer provides the necessary oxygen permeability for separation efficiency, while the second barrier layer provides chemical compatibility with various photopolymer substances. This segmentation resolves the contradiction by assigning different functions to different layers.
Solution Approach 2:
The barrier layer acts as an intermediary between the photopolymer and the oxygen-permeable elastic layer. It allows oxygen to pass through for separation while preventing direct contact and potential degradation reactions between the photopolymer and the elastic material, thus maintaining both separation efficiency and versatility.
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 laminated multi-material separation layer effectively reduces the force needed to separate parts from the container, maintains the mechanical and optical properties of the separation layer, and extends the effective working lifetime of photopolymer containers by preventing degradation, resulting in improved resolution and accuracy of the fabricated parts.
Implementation Method 1
the second material layer having an oxygen permeability of at least 10 Barrer and forming the exposed surface of the container
Implementation Method 2
a first material layer bonded to at least a portion of the transparent region of the interior bottom surface
Implementation Method 3
configured to fabricate parts by curing a liquid photopolymer to form layers of cured photopolymer
Data Source
AI summary
According to some aspects, a container is provided for use in an additive fabrication device configured to fabricate parts by curing a liquid photopolymer to form layers of cured photopolymer. The container may comprise a laminated multi-material layer having an elastic first layer that aids in separation of cured photopolymer from the container in addition to a barrier layer on an upper surface that protects the first layer from exposure to substances in the liquid photopolymer that may not be compatible with the material of the first layer.