Shaping Plate with Water-Soluble Layer for Additive Manufacturing
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Solution Overview
Problem
In additive manufacturing, it is challenging to remove shaped materials from a shaping stage without deforming them, as direct force application can affect the stage's accuracy and integrate the material with the stage, making separation difficult.
Innovation Solution
A shaping plate with a water-insoluble base substrate and an underlying layer containing a water-soluble material on at least one surface, featuring through holes that allow a solvent to easily contact and dissolve the underlying layer, facilitating the separation of the shaped material without applying physical force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the shaped material is formed directly on the shaping stage, then the shaping process is simple, but it becomes very difficult to remove the shaped material without applying force that affects stage accuracy
Solution Approach 1:
The invention introduces a shaping plate as a separate component that can be detached from the shaping stage. The shaped material is formed on this removable plate rather than directly on the stage, enabling easy separation without applying force to the stage itself. This segmentation resolves the contradiction by maintaining simple shaping processes while enabling easy material removal through plate detachment.
Solution Approach 2:
The shaping plate acts as an intermediary between the shaping stage and the shaped material. It provides a surface for material formation that can be easily separated from both the stage and the finished object, solving the dual problem of maintaining stage accuracy and enabling material removal.
2Ease of operation
If a release agent is applied to the shaping surface, then the object can be easily removed from the stage, but it becomes difficult for the first layer of shaping material to adhere to the shaping surface
Solution Approach 1:
The invention divides the release function from the shaping surface by introducing a separate shaping plate with an underlying layer. This layer provides the release properties needed for easy removal, while the shaping plate itself serves as the adhesion surface for the first layer of material, eliminating the conflict between release and adhesion requirements.
Solution Approach 2:
The underlying layer containing water-soluble material acts as an intermediary between the shaping plate and the shaped material. It provides controlled adhesion during shaping and controlled release during removal through water dissolution, resolving the contradiction between needing strong adhesion for formation and easy release for removal.
3Strength
If the shaped material is integrated with the shaping plate, then the material is firmly held during shaping, but it becomes difficult to separate the material from the plate after shaping
Solution Approach 1:
The invention changes the adhesion parameter dynamically by using a water-soluble underlying layer. During shaping, the layer provides strong adhesion to hold the material firmly. After shaping, water is applied to dissolve the layer, changing the adhesion parameter from high to low and enabling easy separation without force.
Solution Approach 2:
The underlying layer undergoes a phase transition from a solid adhesive state during shaping to a dissolved state when water is applied. This phase change enables the material to be firmly held during formation and easily released after shaping, resolving the contradiction between integration strength and separation ease.
4Ease of operation
If force is applied to the shaped material during removal, then the material can be separated from the stage, but the shaped material may be deformed
Solution Approach 1:
The invention replaces the mechanical force-based separation system with a chemical dissolution system. Instead of applying mechanical force to separate the material from the plate, water is applied to dissolve the water-soluble underlying layer, enabling separation without mechanical stress and thus preserving the integrity of the shaped material.
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
Enables efficient and accurate separation of shaped materials from the shaping plate using water, reducing the time required and minimizing environmental impact by avoiding physical loads, while maintaining the integrity of the three-dimensional object.
Implementation Method 1
an underlying layer containing a water-soluble material on at least one surface of the base substrate
Data Source
AI summary
A shaping plate to be set on a shaping stage of a shaping system for performing shaping by an additive manufacturing method includes a water-insoluble base substrate and an underlying layer containing a water-soluble material on at least one surface of the base substrate, wherein the base substrate has a plurality of through holes that extend in the direction intersecting the surface provided with the underlying layer.