Selective Melting of 3D Printed Support Particles
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Solution Overview
Problem
Existing methods for manufacturing three-dimensionally formed objects using fluid compositions often result in excessive heat transfer, leading to unnecessary sintering or melting of regions outside the intended object, increasing the number of steps required post-manufacturing.
Innovation Solution
A method involving the use of a fluid composition with constituent material particles and support portion-forming particles, where energy is imparted to achieve temperatures above the melting point of the constituent material but below the support portion-forming particles' melting point, preventing support portion melting and reducing post-manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If energy is imparted to sinter or melt the layer corresponding to the three-dimensionally formed object, then the object can be formed, but other regions of the layer are also sintered or melted due to heat generated, increasing post-manufacturing load
Solution Approach 1:
The layer is segmented into two distinct types: constituent material particles (to be melted) and support portion-forming particles (to remain solid). This segmentation allows selective energy absorption and phase change, enabling the object to be formed without melting the support regions, thereby reducing post-manufacturing extraction steps.
Solution Approach 2:
Different regions of the layer are assigned different material properties: the region corresponding to the three-dimensionally formed object contains constituent material particles with lower melting points, while other regions contain support portion-forming particles with higher melting points. This local differentiation enables selective melting and reduces unnecessary post-processing.
2Manufacturing precision
If temperature is raised above melting point of constituent material, then object formation is enabled, but support portion-forming particles may melt, increasing process complexity
Solution Approach 1:
The melting points of the two particle types are deliberately differentiated: constituent material particles have a lower melting point (e.g., 100-500°C) while support portion-forming particles have a higher melting point (e.g., 500-2000°C). By controlling the energy impartation temperature within this range, selective melting is achieved, ensuring object formation while maintaining support portion integrity.
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 minimizes the load associated with melting other regions, reducing the number of steps needed after object formation and ensuring high precision by maintaining distinct layer thicknesses and porosities.
Implementation Method 1
imparting energy to the constituent material particles and the support portion-forming particles, in which in the imparting of the energy, the energy is imparted such that a temperature of the constituent material particles and a temperature of the support portion-forming particles are equal to or higher than a melting point of the constituent material particles and are lower than a melting point of the support portion-forming particles
Data Source
AI summary
A method of manufacturing a three-dimensionally formed object includes: forming a layer using a flowable composition including constituent material particles of a three-dimensionally formed object and a flowable composition including support portion-forming particles for forming a support portion which supports the three-dimensionally formed object during the formation of the three-dimensionally formed object; and imparting energy to the constituent material particles and the support portion-forming particles, in which in the imparting of the energy, the energy is imparted such that a temperature of the constituent material particles and a temperature of the support portion-forming particles are equal to or higher than a melting point of the constituent material particles and are lower than a melting point of the support portion-forming particles.