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Comprehensive performance of a low-cost spring-assisted mechanism for digital light processing

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Abstract

In additive manufacturing, separation is an important issue in constrained-surface digital light processing. A force higher than the force peak and a sharp increase in force increase the printing failure rate. This study comprehensively evaluated the performance of a low-cost spring-assisted separation mechanism. The Taguchi method was used to confirm the correlation between the inputs of the spring-assisted mechanism (number, coefficient, working height, free height of spring, and length of working arm) and obtain the parameters that minimize the separation force and time. Compared to the pulling-up and tilting mechanisms, the spring-assisted mechanism reduces the difference between the maximum and minimum separation forces for different geometric shapes and areas by 2.4 and 3 times, respectively. In addition, the spring-assisted mechanism solves the problems of the pulling-up mechanism, which has two separation force peaks, and the tilting mechanism, which has a sharp increase in force before the final separation. Finally, the separation force of specific geometric shapes and areas was predicted by the linear regression equation, and the error rate was maintained within 5%, which helped to significantly reduce the calculation costs and time.

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Acknowledgements

The authors would like to thank the National Science and Technology Council, R.O.C., for financial support (MOST 111-2621-M-110-001 and MOST 110-2622-E-027-029).

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Authors and Affiliations

  1. Program in Interdisciplinary Studies, National Sun Yat-Sen University, Kaohsiung, 80424, Taiwan

    Cheng-Jung Yang & Sin-Syuan Wu

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  1. Cheng-Jung Yang
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  2. Sin-Syuan Wu
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Correspondence to Cheng-Jung Yang.

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Highlights

1. Comprehensively evaluated the performance of a low-cost spring-assisted mechanism for the separation process.

2. The Taguchi method was used to confirm the correlation between the inputs of the spring-assisted mechanism (number, coefficient, working height, free height of spring, and length of working arm) and obtain the parameters that minimize the separation force and time.

3. Compared to the pulling-up and tilting mechanisms, the spring-assisted mechanism reduces the difference between the maximum and minimum separation forces for different geometric shapes and areas by 2.4 and 3 times, respectively.

4. The spring-assisted mechanism solves the problems of the pulling-up mechanism, which has two separation force peaks, and the tilting mechanism, which has a sharp increase in force before the final separation.

5. The separation force of specific geometric shapes and areas was predicted by the linear regression equation, and the error rate was maintained within 5%, which helped to significantly reduce the calculation costs and time.

Appendices

Appendix 1

Table 10 Corresponding intervals of degrees of freedom
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Appendix 2

Table 11 Sound-to-noise ratio of separation time
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Table 12 Response to separation time factors
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Fig. 12
figure 12

Response to separation time factors

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Table 13 ANOVA of separation time
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Appendix 3

Table 14 Separation force with the spring-assisted mechanism for molds of different areas
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Table 15 Separation force with the spring-assisted mechanism for molding a triangle
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Table 16 Separation force with the spring-assisted mechanism for molding a pentagon
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Table 17 Separation force with the spring-assisted mechanism for molding a hexahedron
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Table 18 Separation force with the spring-assisted mechanism for molding a circle
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Table 19 Separation force with the spring-assisted mechanism for molding a donut
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Table 20 Statistical results of separation forces for molding a triangle, pentagon, and hexahedron
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Table 21 Statistical results of separation forces for molding a circle and donut
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Yang, CJ., Wu, SS. Comprehensive performance of a low-cost spring-assisted mechanism for digital light processing. Int J Adv Manuf Technol 125, 4099–4118 (2023). https://doi.org/10.1007/s00170-023-10977-2

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