3D Printer Linear Constraining Body for Layer Separation
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Solution Overview
Problem
Conventional three-dimensional modeling apparatuses using the constrained-surface method face challenges in accurately separating cured resin layers from the constraining glass surface, leading to potential object collapse, flatness deterioration, and inconsistent layer thickness due to contraction forces and high viscosity of light-curing resins.
Innovation Solution
A three-dimensional modeling apparatus featuring a constraining body with a linear surface that allows for precise separation of cured layers by moving the stage and constraining body relative to each other along different directions, using a slit region for curing and separation, which enhances flatness and thickness control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the area to be modeled for each layer becomes larger, then the productivity increases, but the power necessary for separation becomes larger causing object collapse or separation from seat
Solution Approach 1:
The constraining body is divided into a first constraining body and a second constraining body that can move relative to each other in the stacking direction. This segmentation allows the system to handle larger modeling areas by distributing the constraining function across multiple movable components, reducing the separation power required for each individual component.
Solution Approach 2:
The second constraining body is configured to move in the stacking direction relative to the first constraining body, creating a dynamic constraint system. This dynamic configuration enables adaptive separation forces that scale with the modeled area, preventing object collapse while maintaining productivity.
2Productivity
If the area to be modeled for each layer becomes larger, then the productivity increases, but the glass may be strained or pulled and deflected toward the resin deteriorating flatness
Solution Approach 1:
The constraining body is segmented into multiple parts that can move independently in the stacking direction. This segmentation distributes the strain and prevents deflection of any single constraining surface, maintaining flatness even when modeling larger areas.
Solution Approach 2:
The movable second constraining body dynamically adjusts its position to compensate for strain distribution across larger areas, preventing the glass from being pulled or deflected toward the resin and thereby maintaining layer flatness.
3Manufacturing precision
If the viscosity of the light-curing resin becomes higher, then the manufacturing precision improves, but the pressure that the resin applies to the seat surface or glass surface becomes higher causing glass strain and thickness control issues
Solution Approach 1:
The movable second constraining body dynamically responds to pressure changes caused by high-viscosity resin, adjusting its position to maintain consistent spacing from the seat surface. This dynamic adjustment prevents glass strain and ensures accurate thickness control despite variations in resin viscosity.
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
Enables neat separation of cured layers, improves flatness, and achieves high accuracy in controlling layer thickness, reducing the risk of object collapse and deformation.
Implementation Method 1
a stereo lithography in which light-curing resin is selectively irradiated with laser light so that desired parts of the resin are cured
Data Source
AI summary
Provided is a three-dimensional modeling apparatus including a stage, a constraining body, a supply nozzle, an irradiation unit, and a movement mechanism. The constraining body includes a surface including a linear region along a first direction, and is opposed to the stage so that the linear region is the closest to the stage. The supply nozzle supplies a material curable by energy of an energy ray into a slit region between the stage and the linear region. The irradiation unit irradiates the supplied material with the energy ray through the constraining body. The movement mechanism moves the stage relative to the constraining body along a second direction for forming a cured layer of the material for one layer, and moves the constraining body and the stage relative to each other along a stacking direction for stacking the cured layers.