Additive Manufacturing Warped Intermediate Object Curing
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Solution Overview
Problem
Conventional additive manufacturing techniques using dual cure resins often require supports, which waste material and slow production, and objects with deep orientations can be inefficiently produced, limiting design freedom.
Innovation Solution
Producing an intentionally warped intermediate object through additive manufacturing and then restoring its shape using a corresponding form during further curing, which eliminates the need for supports and allows for more rapid orientation and production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If supports are used in additive manufacturing, then the object can be produced with complex geometries, but resin material is wasted and production speed decreases
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-distorting the digital model of the object before manufacturing. The model is intentionally warped in the digital domain to compensate for expected deformation during curing, eliminating the need for physical supports during the manufacturing process.
Solution Approach 2:
The patent changes the geometric parameters of the intermediate object by applying a distortion transformation to the original model. This parameter change allows the object to be manufactured without supports while still achieving the desired final geometry after curing deformation.
2Adaptability or versatility
If supports are used in additive manufacturing, then the object can be produced with complex geometries, but resin material is wasted
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-distorting the digital model of the object before manufacturing. The model is intentionally warped in the digital domain to compensate for expected deformation during curing, eliminating the need for physical supports during the manufacturing process.
Solution Approach 2:
The patent changes the geometric parameters of the intermediate object by applying a distortion transformation to the original model. This parameter change allows the object to be manufactured without supports while still achieving the desired final geometry after curing deformation.
3Loss of substance
If the object is oriented for production to minimize supports, then support material is reduced, but the object may present a deep orientation for additive manufacturing
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-distorting the digital model of the object before manufacturing. The model is intentionally warped in the digital domain to compensate for expected deformation during curing, eliminating the need for physical supports during the manufacturing process.
Solution Approach 2:
The patent changes the geometric parameters of the intermediate object by applying a distortion transformation to the original model. This parameter change allows the object to be manufactured without supports while still achieving the desired final geometry after curing deformation.
4Productivity
If the object is oriented with a flat surface for production, then production speed is enhanced and supports are minimized, but not all objects have such geometry
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-distorting the digital model of the object before manufacturing. The model is intentionally warped in the digital domain to compensate for expected deformation during curing, eliminating the need for physical supports during the manufacturing process.
Solution Approach 2:
The patent changes the geometric parameters of the intermediate object by applying a distortion transformation to the original model. This parameter change allows the object to be manufactured without supports while still achieving the desired final geometry after curing deformation.
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 method reduces the need for supports, enhances production speed, and allows for the creation of objects that would otherwise be difficult to produce due to size or flexibility constraints, while maintaining desired mechanical properties.
Implementation Method 1
construction of a three-dimensional object is performed in a step-wise or layer-by-layer manner. Typically, layer formation is performed through solidification of photo curable resin under the action of visible or UV light irradiation
Implementation Method 2
the step of removing those supports slows production, and can leave undesirable artifacts on the final object. An additional problem can be the need to orient the object for production
Data Source
AI summary
Provided is a method of making a three-dimensional object, which method may include the steps of: (a) producing an intermediate object (21) from a dual cure polymerizable liquid by additive manufacturing, the intermediate object having the shape of the three-dimensional object in warped or distorted form; (b) optionally washing the intermediate object; then (c) contacting the intermediate to a form (22), which form has a shape corresponding to the three-dimensional object, and with the intermediate conformed to the shape of the form; then (d) further curing the intermediate object in contact with the form to produce the three-dimensional object (24) under conditions in which the three-dimensional object retains a shape conformed to the form after separating therefrom; and then (e) separating the three-dimensional object from the form.