Sacrificial Structure with Heating Cells for Additive Manufacturing Curling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Additive manufacturing techniques, such as 3D inkjet printing, often experience undesired deformation, specifically curling of the edges, in the final manufactured objects due to temperature gradients and material properties, which existing solutions have not fully addressed.
Innovation Solution
A method and system that utilize a sacrificial structure with embedded heating cells and pinning structures, comprising different materials with varying heat deflection temperatures, to support the object and reduce curling by managing temperature gradients and material stress during the printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive manufacturing is used, then manufacturing capability is achieved, but curling deformation occurs in the final object
Solution Approach 1:
The patent applies preliminary action by creating a sacrificial structure with heating cells and pinning structures before manufacturing the final object. The heating cells are positioned in advance to generate heat that prevents curling, and pinning structures are pre-formed to provide mechanical support. This preliminary preparation eliminates curling deformation during the manufacturing process without compromising manufacturing capability.
Solution Approach 2:
The patent uses an intermediary approach by introducing a sacrificial structure as a mediator between the manufacturing process and the final object. This sacrificial structure includes heating cells that act as thermal intermediaries to control temperature gradients, and pinning structures that serve as mechanical intermediaries to prevent deformation. The sacrificial structure is eventually removed after serving its protective function.
2Temperature
If heating cells with high heat release material are used, then temperature management improves, but device complexity increases
Solution Approach 1:
The patent applies local quality by concentrating heating functionality in specific localized cells rather than uniformly distributing thermal management throughout the entire structure. The heating cells are strategically positioned at locations where temperature control is most critical, and contain material formulations with specific thermal properties. This localized approach provides effective temperature management while minimizing overall structural complexity.
Solution Approach 2:
The patent utilizes parameter changes by varying the material properties of different regions within the sacrificial structure. Heating cells contain material formulations with different thermal parameters (heat release characteristics, thermal conductivity) compared to the surrounding bulk material. This parameter variation enables precise temperature control without requiring complex external heating systems.
3Manufacturing precision
If pinning structures are added to support the object, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The patent merges the support function with the sacrificial structure by integrating pinning structures directly into the sacrificial material framework. Rather than adding separate support mechanisms, the pinning structures are combined with the sacrificial structure's geometric features, allowing simultaneous achievement of structural integrity and object support. This merging approach improves manufacturing precision while avoiding additional complexity from separate support systems.
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 proposed method effectively reduces curling in additive manufacturing by using a sacrificial structure with voxel elements and pinning structures, ensuring better support and temperature management, resulting in more stable and accurately formed three-dimensional objects.
Implementation Method 1
heating cells made of a modeling material that releases more heat than the bulk volume upon the solidification of the layers
Data Source
Figure 1A
Figure 1B~1C
Figure 1D
AI summary
A method of additive manufacturing of a three-dimensional object, comprises: sequentially dispensing and solidifying layers to form on a surface a sacrificial structure. In embodiments the sacrificial structure comprises a bulk volume and heating cells embedded in the bulk volume, where the heating cells release more heat than the bulk volume upon the solidification of the layers. In embodiments, the sacrificial structure comprises pinning structures embedded in the bulk volume. The method also comprises sequentially dispensing and solidifying layers to form the three-dimensional object on a portion of the sacrificial structure.