Powder Layer Shaping with Binder Flow Suppression
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The binding liquid in conventional three-dimensional shaping methods tends to exude outside the desired region, leading to reduced shaping accuracy due to variations in powder particle diameter and capillary size, making it difficult to control the spread of the binding liquid accurately.
Innovation Solution
A shaping device and method that incorporates a first liquid application unit for applying a binding liquid and a second liquid application unit for applying a suppressing liquid with higher permeability to the powder layer, controlled by a control unit to prevent the exudation of the binding liquid, using inkjet heads for precise droplet application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a binding liquid is applied to a powder layer to form cross-sectional members, then the powder particles are bonded together to create three-dimensional objects, but the binding liquid exudes outside the desired portion causing cross-sectional members to expand beyond the desired size
Solution Approach 1:
A suppressing liquid is introduced as an intermediary substance applied to the boundary regions of the powder layer. This suppressing liquid prevents the binding liquid from exuding beyond the desired cross-sectional member boundaries by creating a barrier effect, thereby maintaining shaping accuracy while allowing adequate bonding within the target region
Solution Approach 2:
The powder layer is treated with different liquid properties in different regions: the binding liquid is applied to the region where cross-sectional members are to be formed, while the suppressing liquid is applied to the boundary regions. This local differentiation of liquid application ensures precise control over where bonding occurs and prevents unwanted exudation
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 use of a suppressing liquid with higher permeability suppresses the flow of the binding liquid, enhancing shaping accuracy by controlling its penetration and exudation, resulting in improved precision of the three-dimensional objects.
Implementation Method 1
the second liquid is a liquid having higher permeability to the powder layer than the first liquid
Data Source
AI summary
A shaping device for producing a layered body by repeatedly performing a step of forming a powder layer and a step of fixing powder in at least a partial region of the powder layer includes a first liquid application unit configured to apply a first liquid including a binder for binding the powder, a second liquid application unit configured to apply a second liquid for suppressing a flow of the first liquid, and a control unit that controls the first liquid application unit and the second liquid application unit so that where the powder in a first region of the formed powder layer is to be fixed, the first liquid is applied to the first region and the second liquid is applied to a second region adjacent to the first region. The second liquid is a liquid having higher permeability to the powder layer than the first liquid.