3D Printed Modeled Body Border Density Control
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Solution Overview
Problem
Existing 3D modeling techniques face challenges in achieving high modeling accuracy due to difficulties in effectively removing sacrificial bodies from sintered objects without causing fractures or shape loss, particularly at the border areas between the modeled body and the sacrificial body.
Innovation Solution
A method involving a 3D modeling apparatus that applies a modeling solution to each layer of powder, ensuring a lower density at the border area between the modeled body and the sacrificial body, which is then sintered to create a strong yet removable interface, allowing for precise removal of the sacrificial body without fracturing the modeled body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the density of powder at the border area is increased to match the modeled body area, then the strength of the border area is improved, but the ease of removing the sacrificial body deteriorates
Solution Approach 1:
The patent applies different powder densities to different regions: the border area has lower powder density compared to the modeled body area. This local quality differentiation allows the border to have sufficient strength for handling while maintaining ease of sacrificial body removal, as the lower density creates a natural separation interface.
Solution Approach 2:
The border area with reduced powder density acts as an intermediary zone between the modeled body and the sacrificial body. This intermediate region facilitates the removal process by providing a weakened interface that allows clean separation without requiring excessive force that could damage the modeled body.
2Ease of manufacture
If the density of powder at the border area is decreased to facilitate sacrificial body removal, then the ease of removing the sacrificial body is improved, but the strength of the border area deteriorates
Solution Approach 1:
The border area is intentionally given different (lower) powder density compared to the main modeled body area. This local quality variation creates an optimized interface that is weak enough for easy sacrificial body removal but maintains sufficient structural integrity for handling the green body.
Solution Approach 2:
The powder density is segmented into at least two regions: a first density for the border area and a second density for the modeled body area. This segmentation allows each region to have properties optimized for its specific function - the border for easy separation and the main body for structural strength.
3Device complexity
If uniform powder density is applied throughout the solidified object, then the manufacturing process is simplified, but the precision of modeling deteriorates due to fractures or shape loss at border areas
Solution Approach 1:
Instead of uniform powder density, the patent implements local quality variation with at least two different powder densities - a first density for the border area and a second density for the modeled body area. This approach maintains manufacturing simplicity while significantly improving modeling precision by preventing fractures and shape loss at the border areas.
Solution Approach 2:
The powder application process is segmented into at least two density zones. This segmentation strategy maintains relatively simple manufacturing procedures while achieving high modeling accuracy by creating an optimized border region that prevents defects during sintering and sacrificial body removal.
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 enhances modeling accuracy by ensuring the strength of the border area while facilitating easy removal of the sacrificial body, reducing the risk of fracture and shape loss during the sintering process.
Implementation Method 1
applying a modeling solution to each layer of powder laid in a layer, to solidify the powder to which the modeling solution is applied
Implementation Method 2
sintering the solidified object modeled at the modeling to obtain a sintered body of the solidified object
Data Source
AI summary
A method of manufacturing a modeled body includes: modeling including applying a modeling solution to each layer of powder laid in a layer, to solidify the powder to model a solidified object; sintering the solidified object to obtain a sintered body of the solidified object; and removing a sacrificial body from the sintered body, to obtain a modeled body. At the modeling, the modeling solution is applied to a modeled body area in the solidified object and a border area in the solidified object such that, after the modeling solution is applied, a density of the powder at the border area is smaller than a density of the powder in the modeled body area. The modeled body area corresponds to the modeled body. The border area corresponds to a border between the modeled body and the sacrificial body.