Three-Dimensional Shaping Device With Timed Layer Curing
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Solution Overview
Problem
Existing three-dimensional shaping devices face challenges in uniformly cooling shaping layers, leading to potential collapse due to incomplete curing when a new layer is formed before the previous layer is fully cured.
Innovation Solution
A three-dimensional shaping device with a heater covering the shaping region, a head for dispensing material, a movement mechanism, and a control unit that controls the dispensing and cooling processes, including a waiting period to ensure complete curing of each layer before forming the next.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling unit is provided in the vicinity of the nozzle to cool the melted material, then the curing of the shaping layer is promoted, but only the shaping layer in the vicinity of the nozzle is cooled and the entire layer cannot be sufficiently cooled
Solution Approach 1:
The cooling process is segmented into multiple stages: initial cooling near the nozzle during material dispensing, followed by extended cooling after dispensing stops. The control unit divides the cooling period into a first cooling period (during material dispensing) and a second cooling period (after dispensing stops), allowing different cooling strategies for different phases of the shaping layer formation.
Solution Approach 2:
The cooling action is performed preliminarily during the material dispensing phase, but the control unit extends the cooling action to continue after dispensing stops. By setting a predetermined time period after dispensing stops and continuing cooling during this period, the system ensures that the entire shaping layer is sufficiently cooled before the next layer is formed.
2Productivity
If the melted material is dispensed onto the n−1 layer before the entire n−1 layer is cured, then the shaping process continues efficiently, but the shape of the n−1 layer collapses
Solution Approach 1:
The control unit implements feedback control by monitoring the time elapsed since dispensing stops and comparing it against the predetermined time required for complete curing. Based on this feedback, the control unit determines when to stop dispensing material onto the n−1 layer, ensuring the layer is fully cured before the next layer is formed, thus preventing collapse while maintaining efficient production.
Solution Approach 2:
The system performs preliminary cooling action during the dispensing phase and extends it to continue after dispensing stops for a predetermined time. This preliminary and extended cooling ensures the n−1 layer is fully cured before the n layer is formed, preventing shape collapse while allowing continuous efficient production.
3Loss of time
If dispensing stops immediately after forming the n layer, then the process time is minimized, but the n−1 layer may not be fully cured
Solution Approach 1:
The control unit sets a predetermined time period after dispensing stops to ensure complete curing of the n−1 layer. During this predetermined time, the cooling action continues, and only after this period expires does the system proceed to form the next layer. This ensures curing completeness while minimizing unnecessary delays.
Solution Approach 2:
The control unit changes the time parameter by setting a predetermined time period that extends beyond the immediate dispensing completion. This time parameter adjustment ensures the n−1 layer is fully cured before the next layer is formed, balancing curing reliability with process 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
Ensures uniform cooling and complete curing of each layer, reducing the risk of shape collapse and enhancing adhesion between layers.
Implementation Method 1
a heater covering a shaping region of the stage and facing the stage
Implementation Method 2
determination processing of determining whether a predetermined time is elapsed since the dispensing stop processing is performed
Data Source
AI summary
A three-dimensional shaping device includes: a stage, a heater, a head, a movement mechanism, and a control unit. The control unit is configured to perform first shaping layer forming processing of forming a first shaping layer by controlling the head and the movement mechanism to dispense the shaping material from the head, dispensing stop processing of stopping dispensing of the shaping material from the head by controlling the head, determination processing of determining whether a predetermined time is elapsed since the dispensing stop processing is performed, and second shaping layer forming processing of forming a second shaping layer on the first shaping layer by controlling the head and the movement mechanism to dispense the shaping material from the head when it is determined in the determination processing that the predetermined time is elapsed. The control unit is configured to set the predetermined time based on information related to a shaping time of the first shaping layer.