3D Printing Support Shell for Deformation Control
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Solution Overview
Problem
Conventional three-dimensional shaping methods face challenges in removing supporting materials without deforming or collapsing, due to their softness and lack of rigidity, which affects the handling and quality of the final shaped object.
Innovation Solution
A three-dimensional shaping apparatus that uses a supporting shell made of a material with higher rigidity than the supporting material, which is easily removable by dissolving or breaking, allowing for consistent properties of ease of handling and rigidity during shaping, and can be formed concurrently with the model material, reducing fabrication costs and processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the supporting material is made soft and flexible for easy removal, then ease of removal is improved, but the supporting material deforms and deliquesce due to heat and humidity
Solution Approach 1:
The invention uses a composite structure where a rigid shell material (such as resin or ceramic) encases a soft, water-soluble core material. The rigid shell prevents deformation and deliquescence during the shaping process, while the soft water-soluble core allows for easy removal after shaping by dissolving in water. This composite approach resolves the contradiction by combining materials with opposing properties to achieve both structural integrity and ease of removal.
Solution Approach 2:
The supporting material is divided into two distinct functional parts: an outer rigid shell that provides structural support and resistance to environmental factors, and an inner soft water-soluble core that enables easy removal. This segmentation allows each part to fulfill its specific function independently, resolving the contradiction between maintaining rigidity and enabling easy removal.
2Reliability
If the supporting material is made rigid to prevent deformation, then resistance to deformation is improved, but the supporting material becomes difficult to strip off
Solution Approach 1:
The invention employs a composite structure where the outer rigid shell provides the necessary structural support and resistance to deformation, while the inner soft water-soluble core ensures easy removal. The rigid shell is designed to be easily separated from the model material, and the water-soluble core dissolves in water to facilitate complete removal, thus resolving the contradiction between rigidity and ease of removal.
Solution Approach 2:
The supporting material is segmented into an outer rigid shell and an inner soft water-soluble core. The rigid shell maintains structural integrity during shaping, while the water-soluble core is designed for easy removal. This segmentation allows the rigid and removable properties to coexist in separate functional components.
3Strength
If the supporting material is made strong to avoid collapse, then strength is improved, but the supporting material becomes sticky and uncomfortable to handle
Solution Approach 1:
The invention uses a composite structure where a rigid shell material (resin or ceramic) provides the necessary structural strength to prevent collapse, while an inner water-soluble core maintains a non-sticky, comfortable surface for handling. The rigid shell is designed to be easily separable from the model material, and the water-soluble core dissolves in water to complete the removal process, resolving the contradiction between strength and ease of handling.
4Device complexity
If a single material is used for both model and supporting material, then device complexity is reduced, but the supporting material cannot simultaneously exhibit high rigidity and ease of removal
Solution Approach 1:
The invention employs a composite structure combining a rigid shell material (such as resin or ceramic) with a soft water-soluble core material. This composite approach allows the supporting material to exhibit high rigidity through the outer shell while maintaining ease of removal through the water-soluble core, resolving the contradiction without requiring multiple separate supporting material components.
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 the easy removal of supporting materials while maintaining the structural integrity of the shaped object, preventing deformation and deliquescence, and reducing the time required for removal, thus improving the quality and efficiency of the shaping process.
Implementation Method 1
a curing device 24 for curing the model material MA and the supporting material SA
Implementation Method 2
the supporting shell SS may be made of a material having higher rigidity than that of the supporting material SA
Implementation Method 3
which is easily removable by dissolving or breaking
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention facilitates removal of supporting materials, while maintaining ease of handling thereof. A control device performs control for causing a horizontal driving device to reciprocatingly scan a head portion 20 in a single direction, further causing a shaping-material ejection device to eject a model material MA and a supporting material SA and causing a curing device 24 to cure the model material MA and/or the supporting material SA forward or rearward paths during the reciprocating scanning, further for moving positions of the shaping plate 40 and the head portion 20, and for repeating lamination of the slices to perform shaping. The supporting material SA is provided, with a supporting shell SS made of a material different from that of the supporting material SA, and being a material having higher rigidity than that of the supporting material SA.