Segmented Raft Layer for 3D Printing Adhesion and Separation
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Solution Overview
Problem
Existing methods for manufacturing three-dimensional objects face challenges in modeling an appropriate raft layer that prevents object separation from the stage and maintains quality, as the optimal configuration depends on the stage and object's shape and material, leading to a need for a technique that can adapt the raft layer based on specific conditions.
Innovation Solution
A method involving a first modeling step to create a raft layer with a base layer in contact with the stage and a contact layer above, using different materials, depositing pitches, separation distances, and modeling patterns, and a second step to deposit the object layer, allowing for separation of the raft layer after completion, ensuring appropriate adhesion and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a raft layer is modeled to prevent object separation from the stage, then object stability is improved, but the complexity of modeling conditions increases
Solution Approach 1:
The raft layer is divided into multiple layers (first layer, second layer, third layer) with different modeling conditions. The first layer contacts the stage, the second layer contacts the object, and the third layer is positioned above. Each layer can be independently controlled in terms of material type, depositing pitch, separation distance, and modeling pattern, allowing optimized adhesion for object stability while managing modeling complexity through systematic segmentation.
Solution Approach 2:
Different regions of the raft layer are assigned different properties through separate layers. The first layer uses conditions optimized for adhesion to the stage, the second layer for adhesion to the object, and the third layer for structural support. This local differentiation allows each region to have the specific quality needed, improving overall stability without requiring all regions to meet the most demanding conditions.
2Ease of manufacture
If the raft layer is separated from the object after modeling, then ease of removal is improved, but the risk of quality deterioration increases
Solution Approach 1:
By segmenting the raft layer into multiple independently controllable layers, the contact layer (second layer) can be specifically designed with controlled adhesion properties. This allows the raft layer to be easily separated from the object after modeling while minimizing quality deterioration, as each layer's adhesion characteristics can be optimized for its specific function in the separation process.
3Adaptability or versatility
If different modeling conditions are used for different layers, then adaptability to stage and object characteristics is improved, but the complexity of controlling modeling parameters increases
Solution Approach 1:
The modeling process is segmented into distinct layers, each with independently controllable parameters. This allows the first layer to be optimized for stage contact, the second layer for object contact, and the third layer for structural integrity. The segmentation enables adaptability to different stage and object characteristics through independent parameter control for each layer, while the systematic structure manages the complexity of multi-parameter control.
Solution Approach 2:
Different modeling parameters (material type, depositing pitch, separation distance, modeling pattern) are changed for different layers to optimize performance. The first layer uses parameters optimized for adhesion to the stage, the second layer for adhesion to the object, and the third layer for structural support. This parameter differentiation enhances adaptability to various stage and object characteristics while maintaining manageable control through systematic parameter assignment to each layer.
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 creation of a raft layer that effectively prevents object separation from the stage and maintains quality by adjusting modeling conditions based on the stage and object's characteristics, enhancing the adaptability and reliability of the manufacturing process.
Implementation Method 1
an extruding unit configured to extrude the modeling material
Implementation Method 2
a base layer in contact with the modeling surface and a contact layer disposed above the base layer and to come into contact with the object
Data Source
AI summary
A method for manufacturing a three-dimensional object includes: a first modeling step of extruding a first modeling material to model a raft layer on a modeling surface of a stage; and a second modeling step of extruding a second modeling material and depositing a modeling layer on the raft layer to model an object. The raft layer is separated from the object after the second modeling step is completed. The first modeling step includes at least one of modeling the raft layer by separately modeling a base layer in contact with the modeling surface and a contact layer disposed above the base layer and to come into contact with the object such that at least one of a type of the first modeling material, a depositing pitch, a separation distance in a depositing direction, a modeling pattern, and a condition for layer disposition in a lateral direction is different, and modeling the raft layer by separately modeling a first layer and a second layer arranged in the lateral direction under different modeling conditions.