Overcure Regions for 3D Printed Dental Objects
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Solution Overview
Problem
Conventional stereolithography (SLA) systems face challenges in removing sacrificial support structures without leaving behind rough support marks, which can cause deviations from the target surface profile and require time-consuming sanding processes.
Innovation Solution
The method involves fabricating a 3D object using additive manufacturing, where a support structure is used during printing. After printing, the object is overcured at specific regions distinct from the support regions, allowing these overcure regions to project past the support marks when the support structures are removed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If support structures are used during printing, then the 3D object can be held securely and positioned correctly, but support marks are left on the surface after removal
Solution Approach 1:
The patent applies preliminary action by creating an indentation in the support structure before printing begins. This pre-formed indentation receives resin material that will later fill the cavity created by support removal, thereby compensating for the support marks in advance and ensuring the final surface profile matches the intended design without requiring post-processing.
2Manufacturing precision
If support marks are sanded to remove them, then the surface profile can be improved, but the sanding process is time-consuming and imprecise
Solution Approach 1:
Instead of requiring time-consuming sanding after printing, the patent incorporates a pre-formed indentation in the support structure that automatically compensates for support marks. The resin material fills this pre-created cavity during printing, eliminating the need for post-printing sanding operations and achieving the desired surface profile directly from the manufacturing process.
3Ease of manufacture
If conventional printing is used, then the process is simple, but support marks cause deviations from the target surface profile
Solution Approach 1:
The patent applies local quality by modifying only the specific region where the support structure contacts the 3D object. An indentation is created locally in the support structure at the contact point, while the rest of the support structure remains unchanged. This localized modification allows the resin to fill the cavity and compensate for support marks without complicating the overall printing process.
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 effectively recesses support marks within the overcure regions, ensuring that the surface of the 3D object conforms to its intended profile without the need for sanding, thus reducing manufacturing time and costs.
Implementation Method 1
a first layer of photocurable resin is irradiated with light to cure the first layer of photocurable resin
Implementation Method 2
the overcure region is irradiated with light to overcure the photocurable resin at the overcure region
Data Source
AI summary
A method of manufacturing a three-dimensional (3D) object comprises: fabricating one or more support structures; fabricating the 3D object on the one or more support structures, wherein the one or more support structures contact the 3D object at one or more support regions of the 3D object; and overcuring the 3D object at one or more overcure regions of the 3D object, wherein the one or more overcure regions are distinct from the one or more support regions. The 3D object is configured such that after removal of the one or more support structures from the 3D object, one or more support marks remain on the 3D object where the one or more support structures had contacted the 3D object, wherein the one or more overcure regions of the 3D object are configured to project past the one or more support marks.