Photocured Sculpted Objects With Recessed Support Removal Traces
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Solution Overview
Problem
Existing photo-sculpting methods require a supporting structure that needs to be removed post-manufacturing, often leaving residues or requiring additional polishing, and the design of sculpted objects to accommodate support removal complicates the process.
Innovation Solution
A method and apparatus that form sculpted objects with support removal traces recessed below the surface, using varying light radiation energy densities to control curing degrees, ensuring easy and residue-free support removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a support structure is formed in photo-sculpting, then the sculpted object can be manufactured, but the support needs to be removed after manufacturing which may cause defects
Solution Approach 1:
The patent applies local quality by creating a shared layer with different curing degree (lower crosslinking density) specifically at the interface between the sculpted object and support, while the rest of the sculpted object maintains normal curing. This localized difference in material properties enables easy support removal without affecting the overall quality of the sculpted object.
2Ease of manufacture
If the bonding portion between sculpted object and support is made weak, then support removal is easier, but support residue remains as protrusion on the sculpted object
Solution Approach 1:
The patent applies preliminary action by pre-forming a recess portion in the sculpted object design before support removal. This recess portion is specifically positioned to accommodate any support residue, ensuring that even if residue remains, it will be within the recess and not protrude from the surface, thus maintaining surface smoothness.
3Adaptability or versatility
If support residue is contained in a recess portion, then protrusion does not interfere with other members, but the sculpted object shape must be specifically designed
Solution Approach 1:
The patent applies segmentation by dividing the sculpted object into distinct functional regions: the main sculpted portion and the shared layer region with lower curing degree. This segmentation allows the support removal trace to be formed in a specific zone without complicating the overall design of the sculpted object, maintaining simplicity while achieving the desired functionality.
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
Facilitates seamless support removal without defects or residues, reducing post-processing efforts and ensuring smooth object surfaces.
Implementation Method 1
a first cured layer serving as part of a support, and radiating light onto the photocurable resin composition to form a second cured layer
Data Source
AI summary
A sculpted object formed from a cured product of a photocurable resin composition includes a sculpted surface, and a support removal trace recessed with respect to the sculpted surface. The support removal trace has a higher surface roughness than a surface roughness of the sculpted surface.