3D Printing Release Layer for Support Removal and Alignment
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Solution Overview
Problem
Lamination type three-dimensional object forming methods face challenges in manufacturing objects with isolated portions, as they require temporary supports that are difficult to automatically remove, especially when producing objects with different shapes, and achieving accurate layer thickness and alignment to ensure structural integrity and accuracy.
Innovation Solution
A method and apparatus for manufacturing a structural body using a laminate forming apparatus with a guide shaft, liquid ejection head, and support member, where a release layer is formed first, followed by lamination of model forming layers, and a support material is injected and solidified between layers, allowing for easy removal of the support and precise alignment, using UV ink and a support material like paraffin wax that can be melted for easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If support is formed from material different from model forming material to enable easy removal, then support removal burden is reduced, but alignment accuracy between patterns becomes significantly more difficult to control
Solution Approach 1:
A release layer is introduced as an intermediary between the support layer and the model forming layer. This release layer acts as a mediator that allows the support (formed from different material) to be easily removed after the model is completed, while the model forming layer can still be properly supported during manufacturing. The release layer prevents direct adhesion between the support and model materials, solving the alignment and removal contradiction.
Solution Approach 2:
The support structure is segmented into multiple layers: a support layer formed from support material, and a release layer formed from release material. This segmentation allows each layer to serve its specific function - the support layer provides structural support while the release layer enables easy removal. The different materials can be selectively removed based on their properties without affecting the model forming layer.
2Manufacturing precision
If grinding is performed on support surface to achieve high accuracy, then shape accuracy is improved, but processing time increases significantly and heat/mechanical stress may deform fine model portions
Solution Approach 1:
The release layer is formed with the correct thickness and surface quality during the initial lamination process, before the model forming layers are built. This preliminary formation of the release layer surface eliminates the need for subsequent grinding operations. The surface is prepared in advance with the appropriate properties to prevent adhesion and ensure accurate layer formation, avoiding time-consuming post-processing and heat-induced deformation.
Solution Approach 2:
The mechanical grinding process is replaced by a chemical/material-based approach. Instead of using mechanical force to remove material and achieve accuracy, the patent uses the selective adhesion properties of the release layer material to achieve the desired surface quality and separation. This substitution eliminates the harmful effects of grinding while maintaining or improving accuracy.
3Stability of the object's composition
If uniform thickness layers are formed from different materials, then material supply accuracy and volume control become significantly more difficult, but layer consistency is maintained
Solution Approach 1:
Different layers are assigned different material properties and functions based on their local requirements. The support layer uses support material with properties optimized for structural support, while the release layer uses release material with properties optimized for non-adhesion and easy removal. This local differentiation allows each material to be supplied and controlled according to its specific needs rather than requiring uniform properties across all layers.
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 enables the manufacturing of structural bodies with high shape accuracy by ensuring precise alignment and easy removal of supports, reducing the burden of support removal and maintaining the strength and quality of the three-dimensional object.
Implementation Method 1
a liquid ejection head 3 for ejecting a liquid material, and a UV irradiation unit 13 for irradiating the liquid material with UV light
Implementation Method 2
when a melting agent which melts a support material but not the model forming material is used, the support can be easily removed
Data Source
Figure 1~2A
Figure 2B~3A
Figure 3B~3D
AI summary
In structural body formation, influence of misalignment between an in-process structural body layer and a support member layer on the shape accuracy is reduced. A method for manufacturing a structural body includes: forming a model forming layer from a liquid model forming material on an existing surface formed of at least one of prepared model forming layer and support member; while a defining surface of a defining member defining the upper surface of the model forming layer is in contact therewith; supplying a support material to fill between the existing surface and the defining surface and solidifying the support material into a support member to form a layer of the model forming layer and the support member; removing the defining member; and providing a layer of a model forming layer and a support member on the surface of the layer exposed by removal of the defining member.