Porous Shaping Stage for 3D Printed Body Sintering Stability

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Solution Overview

Problem

Existing three-dimensional shaped article production methods face deformation issues during degreasing or sintering due to differences in volatilization rates between materials on the shaping stage, leading to uneven shrinkage and potential breakage of the stacked body.

Innovation Solution

A three-dimensional shaped article production apparatus with a shaping stage formed into a porous structure using high-melting point materials like alumina, silicon carbide, or zirconia, and an organic film with a lower melting point, allowing for uniform volatilization and reducing deformation by confining constituent materials within the pores during processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If a stacked body is degreased or sintered to remove material, then the material to be removed is decomposed and removed by volatilization, but the stacked body shrinks and deforms due to difference in shrinkage ratio between different volatilization directions

Engineering Contradiction:

Improvematerial to be removedVSAvoidshape accuracy of stacked body

Core Design Contradiction:

Loss of substanceVSManufacturing precision

Solution Approach 1:

The shaping stage is constructed with a porous structure containing numerous pores that allow volatilized material to escape uniformly from all directions. This porous configuration enables consistent shrinkage throughout the stacked body during degreasing or sintering, preventing deformation while effectively removing the material to be removed.

Inventive Principle:

Principle #31Porous materials

2Ease of operation

If a shaping stage material with low bonding property is used, then the three-dimensional shaped article can be easily removed, but the stacked body still deforms during degreasing or sintering

Engineering Contradiction:

Improveease of removing shaped articleVSAvoidshape accuracy of stacked body

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The porous structure of the shaping stage addresses the deformation issue independently of bonding properties. The pores enable uniform volatilization escape from all directions, ensuring consistent shrinkage and preventing deformation regardless of how strongly the shaped article bonds to the stage.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The invention changes the physical structure parameter of the shaping stage from solid to porous. This structural parameter change fundamentally alters the volatilization dynamics, allowing uniform material removal and consistent shrinkage that prevents deformation while maintaining ease of article removal.

Inventive Principle:

Principle #35Parameter changes

3Temperature

If the shaping stage is made from high-melting point material, then the stage can withstand high temperatures during sintering, but the stacked body may still deform due to uneven shrinkage

Engineering Contradiction:

Improvethermal resistance of shaping stageVSAvoidshape accuracy of stacked body

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The porous structure works in conjunction with high-melting point materials to solve both thermal resistance and shape accuracy requirements. The pores enable uniform shrinkage throughout the stacked body during high-temperature sintering, preventing deformation while the high-melting point material ensures the stage itself remains structurally intact.

Inventive Principle:

Principle #31Porous materials

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

The solution effectively suppresses deformation and breakage of the stacked body by minimizing differences in volatilization rates and allowing for easy separation from the shaping stage, maintaining structural integrity and purity of the three-dimensional shaped article.

Implementation Method 1

a material (a material to be removed) other than a constituent material of the final three-dimensional shaped article is decomposed and removed by volatilization or the like

Methodology Applied

Scientific EffectVolatilization: Evaporation

Implementation Method 2

sintering of a stacked body of a three-dimensional shaped article formed on a shaping stage

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 3

the shaping stage is formed into a porous structure using a high-melting point material having a higher melting point than a constituent material of the three-dimensional shaped article

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP3275575B1Three-dimensional shaped article production apparatus comprising a three-dimensional shaped article shaping stage, and three-dimensional shaped article production method

Publication Date: 2023.08.09 SEIKO EPSON CORP

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Figure 2A~2B
Figure 3

AI summary

A three-dimensional shaped article shaping stage, which is used in a three-dimensional shaped article production apparatus for producing a three-dimensional shaped article by stacking layers to form a stacked body, has a forming surface on which the stacked body is to be formed, and is formed into a porous structure using a high-melting point material having a higher melting point than a constituent material of the three-dimensional shaped article, is used. By using such a shaping stage, it becomes possible to suppress deformation of the stacked body of the three-dimensional shaped article formed by stacking layers on the shaping stage accompanying degreasing or sintering of the stacked body.