UV Curing Ink Shaping Device Partial Cure Control

Solution Overview

Problem

In 3D printing using ultraviolet curing ink, unintended contact between cured ink and the flattening unit can occur due to variations in ink deposition, leading to reduced precision, residue formation, and vibration of the flattening unit, which compromises the shaping process.

Innovation Solution

Adjusting the ultraviolet light exposure in each main scanning operation to ensure the ink is not completely cured, allowing it to maintain fluidity and preventing contact with the flattening unit, while ensuring sufficient curing in subsequent operations to form a stable layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the ultraviolet curing ink is completely cured after each main scanning operation, then the layer stability is improved, but the ink layer becomes too rigid and contacts the flattening unit causing residue formation and precision degradation

Engineering Contradiction:

Improvelayer stabilityVSAvoidshaping precision

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The patent applies partial curing by controlling the ultraviolet light irradiation amount to be less than the full curing threshold. This allows the ink layer to achieve sufficient stability for flattening while maintaining enough fluidity to prevent contact with the flattening unit, thereby avoiding residue formation and maintaining shaping precision

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The patent changes the curing parameter (ultraviolet light irradiation amount) from full curing to partial curing. By adjusting this parameter, the ink layer transitions from a completely rigid state to a semi-cured state that balances stability and fluidity, preventing contact with the flattening unit while maintaining layer integrity

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If the ultraviolet curing ink is not completely cured, then the ink maintains fluidity and prevents contact with the flattening unit, but the layer stability is reduced

Engineering Contradiction:

Improveshaping precisionVSAvoidlayer stability

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The patent applies partial curing by controlling the ultraviolet light irradiation amount to be less than the full curing threshold. This allows the ink layer to achieve sufficient stability for flattening while maintaining enough fluidity to prevent contact with the flattening unit, thereby avoiding residue formation and maintaining shaping precision

Inventive Principle:

Principle #16Partial or excessive action

3Shape

If the flattening unit contacts the cured ultraviolet curing ink, then the ink layer can be flattened, but the cured ink is scraped causing residue formation and environment deterioration

Engineering Contradiction:

Improvelayer flatnessVSAvoidresidue formation

Core Design Contradiction:

ShapeVSObject-generated harmful factors

Solution Approach 1:

The patent applies preliminary action by performing partial curing before the flattening operation. This prepares the ink layer in a semi-cured state that is stable enough for flattening but still fluid enough to prevent scraping and residue formation when the flattening unit makes contact

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the curing parameter (ultraviolet light irradiation amount) from full curing to partial curing. By adjusting this parameter, the ink layer transitions from a completely rigid state to a semi-cured state that balances stability and fluidity, preventing contact with the flattening unit while maintaining layer integrity

Inventive Principle:

Principle #35Parameter changes

4Productivity

If the ultraviolet light irradiation amount is increased to ensure complete curing, then the curing speed is improved, but the ink layer becomes too rigid and contacts the flattening unit

Engineering Contradiction:

Improvecuring speedVSAvoidshaping precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent optimizes the ultraviolet light irradiation amount parameter to achieve partial curing rather than complete curing. This parameter adjustment maintains sufficient curing speed while preventing the ink layer from becoming too rigid and contacting the flattening unit, thereby maintaining shaping precision

Inventive Principle:

Principle #35Parameter changes

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 prevents the scraping of cured ink and residue formation, maintains high precision in shaping, and stabilizes the flattening unit, enhancing the overall 3D printing process.

Implementation Method 1

an ultraviolet curing type ink, which cures by irradiation of an ultraviolet ray

Methodology Applied

Scientific EffectUltraviolet curing: Photopolymerisation

Data Source

PatentUS11260593B2Shaping device and shaping method

Publication Date: 2022.03.01 MIMAKI ENGINEERING CO LTD

AI summary

A shaping device that shapes a 3D object, including: a discharging head that discharges an ultraviolet curing type ink as a material of shaping; an ultraviolet light source; a main scanning driving unit; a sub-scanning driving unit, a flattening roller serving as a flattening unit, and a controller, where the controller causes the inkjet head to carry out the main scanning operation for plural times with respect to each position in a plane orthogonal to a layering direction, and when an integrated light amount of the ultraviolet ray irradiated per unit area in one main scanning operation is defined as a unit area light amount, the unit area light amount in some main scanning operations is made smaller than the unit area light amount in the other main scanning operations in the plural times of main scanning operations carried out with respect to each position.