3D Lamination Regulating Member for Support Removal
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Solution Overview
Problem
Existing 3D lamination modeling methods face challenges in achieving high thickness accuracy and efficiently removing supports from complex shapes, leading to issues with alignment and strength reduction due to the use of different materials for the model and support, which complicates the manufacturing process.
Innovation Solution
A method involving an intermediate transfer member and a regulating member to align and solidify both the modeling and support layers, using a support material that can be easily removed, such as paraffin wax, to ensure accurate lamination and support structure without the need for complex apparatus configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the model portion and support portion are made of different materials to enable easy support removal, then the ease of operation improves, but the alignment precision and thickness accuracy deteriorate
Solution Approach 1:
The patent uses the same material for both the model portion and support portion, ensuring homogeneous properties throughout. This eliminates alignment issues and thickness variation problems that arise from using different materials, while still enabling support removal through the dissolving action of the solubilizer on the support portion.
Solution Approach 2:
The patent introduces a solubilizer as an intermediary substance that selectively acts on the support portion. The solubilizer serves as a mediator that enables differentiation in removal behavior between model and support portions without requiring the portions themselves to be made of different materials.
2Device complexity
If margins are removed after modeling to create support in sheet laminating method, then the device complexity is reduced, but the manufacturing precision deteriorates due to difficulty in removing margins from complicated shapes
Solution Approach 1:
The patent performs preliminary action by forming the support portion together with the model portion during the lamination process itself, rather than removing margins after modeling. The support portion is created in advance as an integrated structure, eliminating the need for post-modeling margin removal and the associated precision problems.
Solution Approach 2:
The patent segments the lamination target into model portion and support portion, with the support portion being formed separately but simultaneously during the lamination process. This segmentation allows the support to be created in advance without interfering with the final model precision, as the support portion is designed to be removed later using the solubilizer.
3Reliability
If support is built during lamination modeling to create isolated portions, then the reliability of creating complex shapes improves, but the loss of time increases due to support removal requirements
Solution Approach 1:
The patent utilizes phase transition concepts through the solubilizer, which causes the support portion to transition from a solid state to a dissolved state. This phase change enables rapid and complete support removal without manual intervention, significantly reducing the time loss associated with support removal while maintaining the reliability of creating complex isolated portions during lamination.
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 high forming accuracy and easy removal of supports, reducing the complexity of the apparatus and minimizing distortions in the final product, ensuring uniform layer thickness and maintaining surface smoothness.
Implementation Method 1
a unit configured to provide a layer constituted by the support member and the modeling layer by making a regulating surface of a regulating member for regulating an upper surface of the modeling layer on the opposite side of a surface which is in contact with the intermediate transfer member abut the upper surface of the modeling layer
Implementation Method 2
solidifying the material for the support member
Implementation Method 3
the support may be removed easily by using a solubilizer which makes the support member dissolve
Data Source
AI summary
A manufacturing method of a structure includes, in this order: providing a layer constituted by a support member and a modeling layer by bringing a regulating surface of a regulating member into contact with the modeling layer provided on a surface of an intermediate transfer member, pouring a material for the support member which becomes the support member to fill the periphery of the modeling layer while the regulating surface abutting the modeling layer, and solidifying the material for the support member; removing the regulating member from the layer constituted by the support member and the modeling layer.