Liquid-Supported 3D Shaping for Support-Free Overhangs
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Solution Overview
Problem
The production of shaped objects using support materials is labor-intensive and costly, with the removal of support materials requiring industrial waste treatment, and the overhang portions are susceptible to gravity-induced deformation.
Innovation Solution
A method and apparatus that uses inkjet technology to eject and cure ink layers in a liquid storage unit, eliminating the need for support materials by utilizing buoyancy and controlled ink layer formation to reduce gravity's influence on overhangs, and incorporating a liquid storage unit with a recess and recovery system to maintain ink landing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If support material is used to shape overhang portions, then the shaped object can be formed with complex geometry, but the production time increases due to support material removal and waste liquid treatment
Solution Approach 1:
The invention extracts and eliminates the support material component from the shaping process. By using a liquid medium instead of solid support material, the system removes the need for support material removal steps and waste liquid treatment, directly resolving the productivity issue while maintaining geometry complexity capability
Solution Approach 2:
The invention changes the physical state of the support medium from solid to liquid. This parameter change allows the medium to provide support through buoyancy and conformability rather than rigid structural support, enabling support material-free shaping of overhang portions and eliminating removal operations
2Reliability
If support material is used to maintain overhang portions, then the shaped object structure can be supported during fabrication, but labor and cost increase due to support material removal and waste liquid processing
Solution Approach 1:
The liquid medium provides self-service support through buoyancy forces that automatically act on overhang portions during the shaping process. This eliminates the need for manual support material application and removal, reducing labor and associated costs while maintaining structural support reliability
Solution Approach 2:
The invention employs hydraulic principles by using a liquid medium to provide support forces through buoyancy. This hydraulic approach replaces solid mechanical support structures, simplifying the manufacturing process and reducing labor requirements for support material handling
3Ease of manufacture
If support material is used to form overhang portions, then the shaped object can be fabricated, but the surface quality deteriorates due to support material influence
Solution Approach 1:
The liquid medium provides localized support only where needed through buoyancy forces, rather than requiring universal support material coverage. This allows the shaped object surface to form without contact with solid support materials, improving surface quality while maintaining fabrication capability
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 reduces labor and costs associated with support material removal, improves surface quality and shaping accuracy, and allows for rapid production of high-quality shaped objects with enhanced properties such as transparency, corrosion resistance, and heat resistance.
Implementation Method 1
buoyancy acts on the portion of the upper ink layer that overhangs the lower ink layer
Implementation Method 2
the ink is ultraviolet curable ink
Data Source
AI summary
To reduce labor and cost in producing a shaped object. A method for producing a shaped object 7 to produce the three-dimensional shaped object 7 includes an ejecting step of ejecting ink from a head unit 2 to a liquid 6 stored in a liquid storage unit 5, and a curing step of curing the ink ejected to the liquid 6 by an ultraviolet curing unit 4.