Truncated Conic Struts for 3D Printing Support Removal
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Solution Overview
Problem
Conventional three-dimensional molding methods face challenges in efficiently removing support structures from the object and base plate after molding, as well as hindrances to squeegee movement due to contact with protruding regions at corners of sintered struts or upper struts.
Innovation Solution
The method employs truncated circular conic shapes or partial truncated circular conic shapes for the upper parts of struts and middle partition plates, which are reduced in diameter toward the top, ensuring efficient removal and minimizing contact hindrances during squeegee movement by forming connection surfaces that are horizontal, curved, or oblique, thus reducing the contact area and allowing for smooth squeegee movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If support structures with straight cylindrical struts are used, then the support structure can effectively support the object from below, but the squeegee contacts with protruding regions at corners of sintered struts and this hinders movement of the squeegee
Solution Approach 1:
The patent applies curvature by changing the strut shape from straight cylindrical to truncated circular conic (tapered) form. The tapered shape with reduced diameter toward the top eliminates protruding corners that interfere with squeegee movement, while maintaining structural support capability through optimized geometry
2Productivity
If support structures are designed for easy removal, then removal efficiency is improved, but the contact area between support and object increases causing hindrance to squeegee movement
Solution Approach 1:
The patent applies local quality by varying the strut diameter along its length - larger diameter at the base for easy removal and smaller diameter at the top for reduced squeegee interference. This gradient geometry optimizes both removal efficiency and operational smoothness at different locations of the same component
3Strength
If the upper parts of struts have larger diameter, then the support strength is improved, but the contact area with squeegee increases causing accidents and hindrances
Solution Approach 1:
The truncated circular conic shape with tapering geometry reduces the top diameter of struts, minimizing contact area with the squeegee and eliminating protruding corners that cause interference, while the base diameter remains sufficient to provide required support strength
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 design enables efficient removal of support structures and prevents hindrances to squeegee movement by reducing the connected section area and allowing for flexible striking directions during removal, ensuring smooth operation and stable support during molding.
Implementation Method 1
a step of sintering a powder layer with a laser light or an electron beam after a flat surface has been formed by sliding of a squeegee against the powder layer is carried out multiple times
Data Source
Figure 1
Figure 2
Figure 3(a)~3(c)
AI summary
A three-dimensional molding method is provided in which a step of sintering a powder layer with a laser light or an electron beam after a flat surface has been formed by sliding of a squeegee against the powder layer is repeated in a prescribed number of times, and then the periphery is cut, to mold both an object to be molded (1) and a plurality of struts (20) that support the lower side of the object from below and are intended to be removed after molding, wherein the upper parts of the struts employ truncated circular conic shapes or partial truncated circular conic shapes that are reduced in diameter toward the top, and wherein at the connection surfaces between the object to be molded and the struts, the directions of the normals at the center coordinates of the connection surfaces coincide with the directions of the central axes of the truncated circular conic shapes or partial truncated circular conic shapes forming the upper parts of the struts, whether the connection surfaces are horizontal or slanted with respect to the horizontal direction.