Variable Profile Extraction Support for Bottom-Up 3D Printing
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Solution Overview
Problem
The existing bottom-up type photo-curing three-dimensional printing technology requires manual removal of integrated supports, which increases production costs, reduces speed, and lowers the quality of printed objects, making it less suitable for applications like orthodontic devices and dental aligners.
Innovation Solution
A bottom-up type photo-curing three-dimensional printing process that uses a variable profile extraction support not chemically and mechanically coupled to the printed object, allowing for the elimination of integrated supports and enabling easy detachment of the printed object without manual removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If integrated supports are formed during printing to support object growth, then the object can be properly formed and supported, but manual removal is required which increases production costs, reduces speed, and lowers quality
Solution Approach 1:
The invention extracts the support function from the final printed object by using a separate, removable support structure. The support is detached after printing, eliminating the need for manual removal of integrated supports and avoiding the associated quality issues at junction points.
Solution Approach 2:
The printing process is segmented into two phases: first printing the support structure, then printing the object on top of it. This segmentation allows the support to be easily removed after the object is formed, avoiding the trade-off between support necessity and production efficiency.
2Reliability
If integrated supports are formed during printing, then the object growth is supported, but the production time increases due to manual support removal
Solution Approach 1:
The support structure is extracted as a separate, temporary element that is removed after serving its purpose during printing. This eliminates the time-consuming manual removal process while maintaining structural support during the critical printing phase.
Solution Approach 2:
The support structure is prepared in advance and positioned before object printing begins. This preliminary action ensures proper support during printing while allowing for quick removal afterward, reducing overall production time.
3Reliability
If integrated supports are formed during printing, then the object can be properly supported, but the unit cost increases due to labor and material consumption
Solution Approach 1:
The support structure is designed as a separate, removable component rather than an integrated part of the final object. This extraction allows for automated or simplified removal processes, reducing labor costs while maintaining support stability during printing.
Solution Approach 2:
The support structure is treated as a temporary, disposable element that is discarded after serving its support function. This approach reduces material costs for the final product and eliminates the need for expensive manual removal operations.
4Manufacturing precision
If manual support removal is required, then the printed object quality deteriorates at junction points, but the process complexity increases
Solution Approach 1:
The support structure is extracted as a separate element that can be easily removed without affecting the quality of the printed object at junction points. This eliminates the need for complex manual removal procedures and maintains high manufacturing precision.
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 process significantly enhances the speed, precision, and mechanical qualities of the final product, reduces production costs, and improves the quality of printed objects by eliminating the need for manual support removal.
Implementation Method 1
forming the support by the polymerisation of a photopolymer material
Implementation Method 2
a support plate, also called extraction plate or build platform... moves to a predetermined distance from the first layer
Data Source
AI summary
The present invention concerns a bottom-up type photo-curing three-dimensional printing process, comprising the following steps:forming a support (11, 33, 41) on an extraction plate (12, 34), by the photo-curing of successive layers of a photopolymer material, the imprint of at least a portion of the object (10, 30, 40) to be formed being formed on said support (11, 33, 41);completing the curing of the photopolymer material of said support (11, 33, 41);forming the object (10, 30, 40) to be printed on said support (11, 33, 41), by the photo-curing of a photopolymer material; anddetaching the obtained object (10, 30, 40) from said support (11, 33, 41).