Additive Manufacturing Method for Variable Solidification Resin Objects
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Solution Overview
Problem
Current additive manufacturing methods for three-dimensional objects using resin-based materials can only achieve limited variations in mechanical properties through different exposure intensities or times, making it difficult to create sections with fundamentally different properties in a single manufacturing process.
Innovation Solution
A method involving two differentiated solidification steps, where a structure section is formed in the first step to delimit an interior with liquid material, and a deformation section with a different degree of solidification is formed in the second step, allowing for the creation of sections with distinct mechanical properties from a single material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different exposure intensities or exposure times are used to solidify different sections, then some variation in mechanical properties can be achieved, but fundamentally different mechanical properties cannot be created in the same manufacturing process
Solution Approach 1:
The manufacturing process is segmented into two distinct solidification steps: a first solidification step that forms a structure section with a first degree of solidification, and a second solidification step that forms a deformation section with a second degree of solidification. This segmentation allows fundamentally different mechanical properties to be created in different sections of the same object using a single resin-based construction material, resolving the contradiction by enabling high adaptability while maintaining manageable process complexity through clear process separation.
2Adaptability or versatility
If multiple construction materials are used to achieve different mechanical properties in different sections, then fundamentally different properties can be created, but the manufacturing process becomes more complex and requires multiple materials
Solution Approach 1:
The invention applies local quality by creating different degrees of solidification within the same construction material at different locations and times. The structure section undergoes first solidification to achieve a first degree of solidification, while the deformation section undergoes second solidification to achieve a second degree of solidification. This allows fundamentally different mechanical properties to be achieved in different sections without using multiple construction materials, thus maintaining material simplicity while achieving property diversity.
3Ease of manufacture
If non-solidified construction material is removed from the object, then the manufacturing process is simpler, but the ability to form deformation sections with different mechanical properties is lost
Solution Approach 1:
The invention applies preliminary action by deliberately leaving non-solidified construction material in the interior after the first solidification step, before proceeding to the second solidification step. This preliminary retention of liquid material enables the formation of deformation sections with different mechanical properties in the second step, while the overall process remains manageable by planning the sequence of solidification steps in advance.
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 formation of objects with varying mechanical properties, such as hard and soft sections, allowing for defined deformation and force transmission, without the need for multiple materials, by using a uniform resin-based construction material.
Implementation Method 1
The construction material is typically changed by a corresponding introduction of energy, in particular by means of radiation, so that it crosslinks or solidifies
Implementation Method 2
In the second solidification step, the liquid construction material in the interior is solidified in order to form the deformation section of the object
Data Source
AI summary
A method for additive manufacturing of an item includes a first solidification step and a second solidification step. In the first solidification step, at least one structure section having a first degree of solidification is formed. The at least one structure section delimits at least one interior accommodating a liquid construction material. The item is a three-dimensional object having a resin-based construction material which is liquid in a base state and is solidifiable. In the second solidification step a deformation section is formed. The deformation section has a second degree of solidification that is different from the first degree of solidification. The deformation section is formed from the liquid construction material accommodated in the interior.