3D Printing Support Layer Stabilization for Binder Jetting Accuracy
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Solution Overview
Problem
Three-dimensional printing technologies face challenges in achieving high accuracy and precision in object manufacturing, particularly in maintaining dimensional stability and shape accuracy during the binding process of successive layers, which affects the quality and reproducibility of the final product.
Innovation Solution
The method involves depositing a support layer followed by a spacer layer, with selective binder deposition to form a stable structure, allowing for improved layer bonding and minimizing disruptive effects on the powder bed, while using different binders and spatial resolutions for the support and object layers to enhance accuracy and material efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If binder is deposited onto successive layers of granular material to bind regions together, then layers are joined to form a three-dimensional structure, but dimensional accuracy and shape precision deteriorate due to disruption of the powder bed
Solution Approach 1:
The patent divides the binding process into two distinct stages: a support layer binding step that stabilizes the powder bed, and a subsequent object layer binding step that achieves high precision. This segmentation allows each stage to be optimized independently - the support layer uses full-area binding for stability, while object layers use selective binding for precision.
Solution Approach 2:
The support layer is deposited and bound before the object layers are formed. This preliminary action stabilizes the powder bed and creates a rigid foundation, preventing disruption during subsequent binder deposition on object layers. The support layer acts as a preparatory structure that enables higher precision in later stages.
2Ease of manufacture
If binder is jetted from the print head onto granular material to selectively bind regions, then layers are joined together, but the powder bed becomes disrupted affecting reproducibility
Solution Approach 1:
The manufacturing process is segmented into support layer formation and object layer formation as separate operations. The support layer binding establishes a stable base, while object layer binding proceeds with high reproducibility because the powder bed is already stabilized and less susceptible to disruption.
3Device complexity
If the same binder is used for all layers, then the process is simplified, but accuracy and material efficiency decrease
Solution Approach 1:
Different binders are used for different functional requirements: the first binder for the support layer is optimized for strong adhesion to the build platform and powder bed stabilization, while the second binder for object layers is optimized for precise binding with minimal disruption. This local differentiation of binder properties enables higher overall precision.
Solution Approach 2:
The patent changes the binder parameter between layers - using different binder materials, concentrations, or deposition parameters for support layers versus object layers. This parameter variation allows optimization for each stage's specific requirements, improving both accuracy and material efficiency.
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 improves the dimensional and shape accuracy of the printed objects by stabilizing the powder bed and optimizing binder distribution, resulting in higher quality and reproducible manufacturing outcomes compared to methods without a support layer.
Implementation Method 1
a liquid binder is jetted from the print head onto the granular material... to selectively bind regions of the build material together
Implementation Method 2
the binder for each layer may need to be cured, for example using ultraviolet light in the case of a UV-curable adhesive
Data Source
Figure 1~3
Figure 4~6
Figure 7~9
AI summary
A method of manufacturing an object (6) is provided. The method comprises depositing a first layer (1) of construction material on a build platform (13). The method comprises depositing binder onto the first layer of construction material to bind at least a region of the first layer together to form a support layer (2). The method comprises depositing a second layer of construction material (3) on the support layer to form a spacer layer. The method comprises depositing a third layer of construction material on the spacer layer (4a). The method comprises depositing binder selectively onto the third layer to bind one or more regions of the third layer together to form a first layer of the object (6). Also provided are data processing methods, program carriers, data processing apparatus and manufacturing apparatus for implementing the method.