3D Printing Support Fixture Porous Design for Drag Reduction
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Solution Overview
Problem
Three-dimensional printing systems using stereolithography face challenges with fluid drag forces on the support fixture, which can damage the resin vessel and hinder operational speed, and there is a need to optimize the build surface materials and minimize fluidic drag to improve the efficiency of the 3D printing process.
Innovation Solution
The introduction of a support fixture with a dense array of small openings on its lower planar portion to minimize fluid drag during the initial stages of printing, and larger openings along the side wall to reduce drag as the printing progresses, along with a magnetic material for secure attachment to the carriage, and a replaceable support system for efficient resin flow and build surface management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the support fixture is moved through the resin at high speed, then productivity is improved, but fluid drag forces increase causing damage to the resin vessel
Solution Approach 1:
The support fixture incorporates a porous lower portion with an array of openings that allow resin to pass through during movement. This reduces fluid drag forces by minimizing resistance between the support fixture and resin, enabling faster operational speeds without damaging the resin vessel while maintaining structural integrity for supporting the build platform.
2Manufacturing precision
If the support fixture uses a solid build surface, then manufacturing precision is maintained, but fluid drag increases reducing operational speed
Solution Approach 1:
The support fixture employs local quality by having a porous lower portion for reduced drag during movement, while the upper build surface maintains solid, smooth characteristics for high manufacturing precision. This spatial differentiation allows the fixture to optimize for both speed (porous bottom) and accuracy (solid top) in different functional zones.
3Device complexity
If the support fixture structure is simplified, then device complexity is reduced, but resin flow management becomes inefficient
Solution Approach 1:
The support fixture is segmented into distinct functional zones: a porous lower portion with optimized opening patterns for efficient resin flow during movement, and a separate upper build surface for artifact fabrication. This segmentation allows each zone to be optimized independently - the lower portion for fluid dynamics and the upper portion for manufacturing precision - without increasing overall device complexity.
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 configuration reduces fluid drag forces on the transparent sheet, minimizes damage to the resin vessel, and enhances the operational speed and efficiency of the 3D printing process by optimizing resin flow and build surface interaction.
Implementation Method 1
The upper portion is provided with a magnetic material for secure attachment to the carriage
Implementation Method 2
The lower planar portion defines a dense array of small openings that minimize a fluid drag of lateral resin motion when the lower build surface is moving vertically
Data Source
AI summary
A support fixture is provided for forming a three dimensional article of manufacture onto a lower build surface thereof. The formation of the three dimensional article occurs in a resin vessel containing photocurable resin. The resin vessel includes a transparent sheet that forms a lower bound for the resin. The support fixture includes an interface fixture and a replaceable support. The interface fixture includes an upper portion having alignment and gripping features, a lower portion surrounding a central opening and including a plurality of attachment features, and a side wall coupling the upper and lower portions. The replaceable support includes a planar portion having a lower surface (providing the lower build surface) for attachment of the three dimensional article of manufacture and a peripheral support portion including complementary attachment features engaging the attachment features when the peripheral support portion is mounted to the lower portion of the interface fixture.