3D Shaping Stage Flatness Control via Segmented Heating
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Solution Overview
Problem
Existing three-dimensional shaping devices face challenges in maintaining the flatness of the shaping stage, which can lead to distortion and collisions between the nozzle and the shaping stage, affecting the accuracy and quality of the shaped objects.
Innovation Solution
A three-dimensional shaping stage with a placement portion having an adjusted reference surface, a shaping stage with a recessed portion, a pressing member to engage with the recessed portion, and a retaining member to prevent rotation and ensure proper positioning, allowing for thermal expansion without distortion and improving flatness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the shaping stage is heated during the three-dimensional shaping process, then the shaping material can be properly cured and bonded, but thermal expansion causes distortion of the shaping stage
Solution Approach 1:
The shaping stage is divided into multiple independent heating regions with separate heating units, allowing different temperature zones to be controlled independently. This segmentation enables localized thermal expansion management while maintaining overall dimensional stability of the shaping surface
Solution Approach 2:
The shaping stage employs an asymmetric structural design where the rigid support frame is positioned differently from the heating elements and shaping surface. This asymmetric layout allows the heating components to expand thermally without transferring distortion to the shaping surface, as the rigid structure provides a stable reference frame that compensates for thermal expansion
2Strength
If the shaping stage is made rigid to maintain flatness, then the nozzle collision can be prevented, but thermal expansion is restricted causing distortion
Solution Approach 1:
The shaping stage structure is segmented into a rigid support frame and a separate heating assembly with the shaping surface. The rigid frame maintains overall structural stability and prevents excessive deformation, while the heating assembly can expand thermally independently without causing distortion to the shaping surface
Solution Approach 2:
A thermal isolation layer or compliant mounting structure is introduced between the heating units and the rigid shaping stage frame. This intermediary component allows thermal expansion of the heating elements while preventing the expansion forces from being transmitted to the shaping surface, thus maintaining flatness during heating
3Manufacturing precision
If the reference surface flatness is adjusted to improve positioning accuracy, then the shaping quality can be enhanced, but the device complexity increases
Solution Approach 1:
The reference surface of the shaping stage is pre-adjusted and pre-calibrated during the manufacturing process to achieve the required flatness and positioning accuracy. This preliminary action eliminates the need for complex adjustment mechanisms during operation, as the shaping stage is delivered in a pre-optimized state that maintains positioning accuracy throughout use
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 solution reduces the likelihood of distortion and enhances the flatness of the shaping surface, preventing collisions and ensuring accurate shaping by allowing for easy positioning and thermal expansion of the shaping stage.
Implementation Method 1
a pressing member including an engaging member engaging with the recessed portion and configured to press the shaping stage in a direction along the shaping surface
Implementation Method 2
a heating unit that heats the shaping material stacked in the shaping region on the stage
Implementation Method 3
a nozzle that dispenses the shaping material toward a shaping region on the stage
Data Source
AI summary
A three-dimensional shaping stage includes: a placement portion having a reference surface whose flatness is adjusted; a shaping stage that has a shaping surface on which a shaping layer is stacked, a first side surface on which a recessed portion is formed, and a second side surface opposite to the first side surface, and that is placed on the reference surface; a pressing member including an engaging member engaging with the recessed portion and configured to press the shaping stage in a direction along the shaping surface; and a retaining member configured to retain the shaping stage on the second side surface.