A rapid prototyping manufacturing process for a modular display

Abstract

This invention discloses a rapid prototyping manufacturing process for modular display racks, belonging to the field of display rack manufacturing technology. The process includes the following steps: S1 Digital Modeling – Establishing a 3D digital model of the entire display rack; S2 Modular Decomposition Design – Dividing the whole into standardized modular units and designing unified connection interfaces; S3 Additive Manufacturing Process Parameter Determination – Selecting FDM / SLS / SLA / MJF processes according to requirements and setting optimization parameters; S4 Slicing Processing and Path Planning – Generating layer data and differentiated printing paths; S5 Additive Manufacturing Molding – Integrating and molding each modular unit and its connection interfaces; S6 Post-processing – Including multiple processes such as precision calibration; S7 Modular Assembly – Rapid tool-free assembly through standardized interfaces. This invention deeply integrates additive manufacturing technology with modular design concepts, achieving integrated molding of connection interfaces and module bodies, significantly shortening the manufacturing cycle, reducing customization costs, supporting complex shapes, and ensuring connection accuracy and reliability for repeated disassembly and assembly, demonstrating significant engineering application value.

Description

Technical Field

[0001] This invention relates to the field of display rack manufacturing technology, specifically to a rapid prototyping manufacturing process for modular display racks, and more particularly to a manufacturing method based on additive manufacturing technology to achieve digital design, integrated molding, and rapid assembly of modular display racks. Background Technology

[0002] As a fundamental infrastructure element in product display, trade show booths, advertising, and museum exhibits, display racks directly impact the efficiency, cost, and visual appeal of exhibition activities through their design and manufacturing methods. With the rise of new retail, the experience economy, and pop-up exhibitions, market demand for display racks exhibits the following significant trends: increasing customization, shorter delivery cycles, more complex designs, and smaller batch sizes. However, existing display rack manufacturing methods face significant technological bottlenecks in addressing these demands.

[0003] The existing methods for manufacturing display racks mainly include the following technical approaches: One method is traditional machining. This involves processing wood or metal profiles (such as aluminum alloy profiles and steel) through sawing, drilling, welding, and bolting. The disadvantages of this method are: (1) Numerous processing steps and long production cycle. Taking a medium-complexity aluminum alloy profile display rack as an example, from receiving the design drawings to the delivery of the finished product, it is necessary to go through multiple processes such as profile cutting (cutting one by one according to the size list), drilling (each connection hole needs to be drilled individually), tapping (thread hole processing), deburring, surface treatment (anodizing or painting), and assembly. A medium-complexity display rack usually takes 7 to 10 days from ordering to delivery, which is insufficient for responding to urgent exhibition needs.

[0004] (2) Customized production is costly. In traditional machining, the processing of irregular structures (such as curved surfaces, inclined surfaces, and irregular holes) requires special tooling fixtures or CNC programming, resulting in extremely high unit costs for small-batch production. For example, machining a non-standard angled connecting hole on an aluminum alloy profile requires custom-made angle fixtures and repeated adjustments, with labor costs 5 to 10 times that of machining a standard hole.

[0005] (3) Low material utilization. The nature of subtractive manufacturing determines that the material utilization rate is limited. In the processing of aluminum alloy profiles, due to cutting losses, drilling waste, and scrap, the material utilization rate is usually only 60% to 70%, resulting in a large amount of material waste.

[0006] (4) Difficulty in achieving complex shapes. Due to limitations in cutting and machining processes, traditional machining methods cannot achieve complex geometric features such as hollow structures, internal mesh reinforcements, and gradient curved surfaces, which greatly restricts the freedom of display rack design.

[0007] The second method is injection molding. The plastic raw material is heated and melted, then injected into a mold cavity. After cooling, it is demolded to obtain the display rack parts. The drawback of this method is: (1) High mold costs. Injection molds require high processing precision and have long manufacturing cycles. The cost of an injection mold for a set of medium-sized display rack parts often exceeds 50,000 yuan, and the cost of a complex structure mold can reach more than 100,000 yuan. For small-batch (such as dozens to hundreds of pieces) customized production, the amortization cost of molds is extremely high, making the cost per piece unacceptable.

[0008] (2) Long mold making cycle. From design, material preparation, rough machining, fine machining, EDM, assembly and debugging to trial molding, injection molds usually take 15 to 30 days. In a fast-paced business environment, this cycle seriously restricts the speed of product launch.

[0009] (3) Structural limitations. Injection molding has strict requirements on the demolding direction, making it impossible to form complex structures with features such as internal undercuts, closed hollow cavities, and large-angle suspensions. Even with complex mold structures such as sliders and angled ejectors, the cost and failure rate of the molds are significantly increased.

[0010] (4) Difficulty in modification. Once the product needs to be adjusted (such as minor size adjustment or addition of new features), the mold needs to be remade or significantly modified, resulting in a huge waste of time and money. This rigid production method is fundamentally contradictory to the current market demand for rapid iteration.

[0011] Thirdly, there are existing technologies for modular display rack systems. In recent years, modular display racks have attracted attention due to their reusability and flexible combination. For example, Chinese patent CN222640196U discloses a deformable modular display rack, using multiple modular components to achieve deformation and combination; Chinese patent CN223140347U discloses a tool-less combination of columns and modular display racks, achieving tool-less connection between columns through plug-in connectors. Although these existing technologies achieve modular combination, the manufacturing of their components still mainly relies on traditional machining or injection molding, thus remaining subject to the inherent defects of these manufacturing methods. Specifically: (1) Limited module types: Due to the high cost of mold opening, injection molding usually only provides a few standardized modules, which cannot meet personalized needs.

[0012] (2) High cost of customization: For modules with non-standard size or special shape, the cost and cycle are high if machining is used, and the investment is huge if a new injection mold is opened.

[0013] (3) Secondary processing of connection interfaces: The connection interfaces (such as slots, card slots, and threaded holes) of existing modular display racks are usually obtained by secondary machining after the module is formed, which has problems such as positioning error and increased processing time.

[0014] Fourthly, there is a booth manufacturing solution based on 3D printing technology. Chinese patent application CN201610852883.0 discloses a booth manufacturing method based on 3D printing technology, proposing the idea of ​​modular disassembly and 3D printing of the booth model. However, this solution only involves general 3D modeling, stress analysis, module disassembly, and printing steps. It lacks sufficient disclosure of key technical details such as the specific structural design of the display rack modules (especially the structural form of the connection interface, tolerance fit, and integrated molding method), the specific molding process parameters of different material systems (FDM, SLS, SLA, MJF), the process selection strategy under different scenarios, and the impact of post-processing on connection accuracy. This makes it difficult for those skilled in the art to directly implement the solution.

[0015] In conclusion, the industry urgently needs a display rack manufacturing process that can balance modular flexibility with the need for rapid customization. This process should fully leverage the complex structural forming capabilities of additive manufacturing technology, achieve efficient, low-cost, and high-precision production of display racks, and provide systematic process solutions for the specific needs of display racks (such as connection strength, assembly accuracy, and durability for repeated disassembly and assembly). Summary of the Invention

[0016] The purpose of this invention is to provide a rapid prototyping manufacturing process for modular display racks, so as to solve the problems of long processing cycle, high customization cost, difficulty in realizing complex structures, limited module types, and insufficient precision of connection interfaces in the existing display rack manufacturing technology.

[0017] To achieve the above objectives, the present invention provides the following technical solution: A rapid prototyping manufacturing process for a modular display rack, characterized by the following steps: Step S1: Digital Modeling – Based on the functional and structural requirements of the display rack, a complete 3D digital model of the display rack is created using computer-aided design (CAD) software. This model includes complete geometric information such as the frame structure, connection nodes, display panel mounting surfaces, decorative elements, and internal channels for accommodating cables or lighting devices. During the modeling process, the constraints of subsequent additive manufacturing processes are considered simultaneously, including but not limited to: angle limitations of suspended structures, minimum wall thickness requirements, space for supporting structures, and the impact of the forming direction of each module unit on mechanical properties.

[0018] Step S2: Modular Design – The overall 3D digital model is modularly disassembled, dividing the display rack into several standardized modular units. Each modular unit is designed with standardized connection interfaces, selected from at least one of the following structures: mortise and tenon joint, snap-lock, dovetail joint, or threaded fastening. Modular units include at least one of the following: frame modules, connection modules, display panel modules, and decorative modules. The following principles must be followed during disassembly: the maximum external dimensions of each modular unit do not exceed the effective forming area of ​​the additive manufacturing equipment; the connection interfaces between modular units use uniform standardized interface dimensions and tolerances; prioritize the use of high-stress areas as independent modules and optimize their forming direction to obtain the best mechanical properties; and disassemble complex shapes into independent modules to reduce overall printing risks.

[0019] Step S3: Determining Additive Manufacturing Process Parameters—Based on the functional requirements of each module unit (structural load-bearing components, decorative appearance components, precision fitting components, etc.) and mechanical performance requirements (tensile strength, flexural strength, impact toughness, etc.), select the appropriate additive manufacturing process type and molding material, and determine the corresponding process parameters. The additive manufacturing process is selected from at least one of Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), Stereolithography (SLA), or Multi-Jet Fused Modeling (MJF). The determination of process parameters requires a comprehensive consideration of the balance between molding quality, production efficiency, and cost.

[0020] Step S4: Slicing and Path Planning – Using slicing software, the 3D digital model of each module unit is sliced, converting the 3D model into layer-by-layer 2D contour data, and generating printing paths and support structure schemes. During slicing, differentiated printing parameters are set according to the functional areas of the module unit (such as precision areas of connection interfaces, main body filling areas, and appearance surface areas) to achieve an optimal balance between quality and efficiency.

[0021] Step S5: Additive Manufacturing Forming – Based on the process parameters determined in Step S3 and the printing path generated in Step S4, additive manufacturing equipment is used to form each module unit layer by layer. During the forming process, the module unit and its connection interface are formed directly in an integrated manner. There are no seams or assembly gaps between the connection interface and the module unit body, thus fundamentally ensuring structural continuity and dimensional accuracy.

[0022] Step S6: Post-processing – Post-processing is performed on each formed module unit, including removing the support structure, surface cleaning, deburring, precision calibration, and / or surface strengthening treatment. The precision calibration step involves precision grinding or micro-fitting of the mating surfaces of the connection interfaces to control the interface clearance within the range of 0.1 to 0.3 mm, ensuring the connection accuracy and structural rigidity after assembly.

[0023] Step S7: Modular Assembly – The post-processed modular units are assembled through their connection interfaces to form a complete modular display rack. The assembly process is manual assembly without tools or with only simple auxiliary tools. The modular units are quickly and reliably connected through mechanical interlocking of the interfaces.

[0024] As a further preferred embodiment, step S2, the modular split design also includes the following details: (1) Design of the column module: The column is the main load-bearing component of the display rack, and its cross-sectional shape can be rectangular, circular, or polygonal. Male and female interfaces are designed at both ends of the column to realize vertical connection between the columns. Multiple horizontal connection interfaces with equal spacing or distributed as needed are opened on the side of the column along the height direction for installing the beam module. A variable density filling strategy can be adopted inside the column, that is, a high filling density (such as 60% to 80%) is used in the area near the connection interface to enhance local strength, and a low filling density (such as 15% to 30%) is used in the middle section area away from the interface to reduce weight.

[0025] (2) Design of the crossbeam module: The crossbeam is used to connect adjacent columns to form a frame structure. The two ends of the crossbeam are designed with connectors that mate with the side interfaces of the columns. The crossbeam cross section can be designed as rectangular, I-shaped or truss type according to the load-bearing requirements. A through cable channel can be designed inside the crossbeam for concealed wiring.

[0026] (3) Design of the connection module: The connection module is used to provide enhanced connection or change the connection angle at the intersection of the column and the beam. The connection module can be L-shaped, T-shaped, cross-shaped or adjustable hinge structure.

[0027] (4) Design of display panel module: The display panel is the load-bearing surface of the exhibits, and its edges are designed with buckles or groove interfaces that cooperate with the crossbeams. The display panel can be designed as a flat plate, curved surface, grid or multi-layer stepped structure.

[0028] (5) Design of decorative modules: Decorative modules are used to enhance the visual effect of the display rack. They can be designed as logo signs, light trough covers, wire trough covers, etc. Their connection interfaces are usually magnetic, snap-on or sliding.

[0029] As another preferred embodiment, when the connection interface in step S2 adopts a mortise and tenon joint structure, its specific structural design is as follows: a tenon structure is provided in one of the module units (such as one end of a column), the tenon protrudes from the end face of the module unit body, the root of the tenon is connected to the module unit body, and the cross-sectional dimension of the tenon gradually decreases in the direction away from the root to form a wedge-shaped guide slope, the slope angle (relative to the insertion direction) is 3° to 10°; a mortise structure that mates with the tenon is provided in another module unit (such as one end of another column or a base), the mortise is a concave cavity, and its inner wall is provided with a locking step or locking protrusion that mates with the wedge-shaped guide slope. When the tenon is inserted into the mortise, the wedge-shaped slope guides the insertion process, and after insertion to a predetermined depth, the locking step and the corresponding shoulder of the tenon form a self-locking mechanism to prevent dislodgement. This structure allows for a certain amount of material elastic deformation to achieve an interference fit, the interference amount is designed to be 0.05 to 0.15 mm.

[0030] As another preferred embodiment, when the connection interface in step S2 adopts a snap-lock structure, its specific structural design is as follows: at least one elastic cantilever is provided on a module unit, and a snap hook is provided at the end of the cantilever; a slot or hole for engaging the snap hook is provided on another module unit that cooperates with the module unit. The thickness of the cantilever is designed according to the elastic modulus of the material to ensure that the cantilever can elastically bend during assembly, allowing the snap hook to enter the slot, and that the cantilever rebounds after assembly, locking the snap hook in the slot. This structure is suitable for applications requiring quick assembly and disassembly, such as the connection between display panels and beams, and the connection between decorative modules and frames.

[0031] As another preferred embodiment, when the connection interface in step S2 adopts a dovetail groove sliding fit structure, its specific structural design is as follows: a dovetail-shaped groove is opened on a module unit, with a dovetail angle (the included angle between the two inclined planes) of 50° to 70°; a dovetail-shaped convex rail with a matching cross-section is provided on another module unit that mates with this module unit. This structure allows the module units to slide along the groove direction and provides mechanical locking perpendicular to the sliding direction, suitable for lateral connections between beams and columns.

[0032] As another preferred embodiment, in step S3, when using fused deposition modeling (FDM), the molding material is selected from at least one of PLA (polylactic acid), PLA+ (reinforced polylactic acid), ABS (acrylonitrile-butadiene-styrene copolymer), ASA (acrylonitrile-styrene-acrylate copolymer), PETG (polyethylene terephthalate-1,4-cyclohexanediol ester), nylon (PA6, PA12), PC (polycarbonate), carbon fiber reinforced composite filaments (such as CF-PLA, CF-PETG, CF-nylon), or glass fiber reinforced composite filaments. The determination of process parameters further includes: Nozzle temperature: determined according to the heat distortion temperature and melt index of the selected material. PLA: 190 to 220°C, PETG: 230 to 250°C, ABS: 230 to 260°C, Nylon: 250 to 280°C, PC: 270 to 300°C.

[0033] Heated bed temperatures: PLA 50 to 60°C, PETG 70 to 85°C, ABS 90 to 110°C, Nylon 80 to 100°C, PC 100 to 120°C.

[0034] Printing speed: 40 to 80 mm / s for the main structure, 20 to 40 mm / s for precision parts such as connecting interfaces, and 15 to 25 mm / s for small features (such as snap-fit ​​cantilever).

[0035] Layer thickness: 0.2 to 0.3 mm for the main structure, 0.1 to 0.15 mm for the outer surface, and 0.1 mm for the precision mating surface of the connection interface.

[0036] Infill density and pattern: 30% to 50% for load-bearing components such as columns, with cubic, honeycomb, or triangular patterns; 10% to 20% for non-load-bearing decorative components, with straight or serrated patterns.

[0037] Outer wall thickness: at least 1.2mm (i.e., 3 layers of 0.4mm line width profile), increased to 2.0mm (5 layers profile) for load-bearing parts.

[0038] Retraction parameters: retraction distance 3 to 6 mm, retraction speed 25 to 45 mm / s, to reduce wire drawing and surface defects.

[0039] Cooling strategy: The cooling fan speed is dynamically adjusted according to the layer printing time. When the layer printing time is less than 10 seconds, the air volume is increased to ensure the shape is set. When the layer printing time is more than 30 seconds, the air volume is reduced to enhance the interlayer bonding force.

[0040] As another preferred option, in step S3, when selective laser sintering (SLS) is used, the molding material is nylon powder (PA12, PA11, PA6), TPU powder (thermoplastic polyurethane), PP powder (polypropylene), or PA12 composite powder (such as glass fiber reinforced, carbon fiber reinforced, or aluminum powder filled). The determination of process parameters further includes: Laser power: determined according to the material melting temperature and powder particle size distribution, 40 to 55W for PA12, 25 to 40W for TPU, and 50 to 65W for glass fiber reinforced PA12.

[0041] Scanning speed: PA12 is 8 to 15 m / s, and contour scanning can reduce the speed by 10% to 20% compared to fill scanning to obtain a smoother surface.

[0042] Layer thickness: typically 0.1 to 0.12 mm, can be reduced to 0.08 mm for high precision requirements, and increased to 0.15 mm for rapid manufacturing.

[0043] Powder bed preheating temperature: set 10 to 20°C below the material melting temperature, typically 168 to 175°C for PA12.

[0044] Scanning interval: 0.2 to 0.3 mm, which needs to be matched with the laser spot diameter to ensure sufficient melting and overlap.

[0045] Energy density control: By comprehensively adjusting the laser power, scanning speed, and scanning spacing, the volume energy density is controlled between 0.2 and 0.4 J / mm². 3 The optimized range is used to avoid under-burning or over-burning.

[0046] As another preferred option, in step S3, when using stereolithography (SLA) process, the molding material is a standard photosensitive resin, an engineering photosensitive resin (ABS-like, PP-like, high-temperature resistant type), a flexible photosensitive resin, or a biocompatible photosensitive resin. The determination of process parameters further includes: Matching laser power and scanning speed: Ensure the curing depth is slightly greater than the layer thickness (typically 1.2 to 1.5 times the layer thickness) to form reliable interlayer crosslinking.

[0047] Layer thickness selection: 0.025 to 0.05 mm for precision parts, and 0.1 mm for standard parts.

[0048] Support structure parameters: The diameter of the support contact point is 0.3 to 0.6 mm, and the contact depth is 0.1 to 0.2 mm, to ensure that the support is stable and easy to remove.

[0049] Secondary curing parameters: UV curing chamber wavelength 365 to 405 nm, curing time determined according to the part wall thickness, 15 to 30 minutes for thin-walled parts (wall thickness less than 3 mm), 30 to 60 minutes for thick-walled parts, curing temperature controlled at 25 to 40℃.

[0050] As another preferred embodiment, in step S3, when using the multi-jet melt molding (MJF) process, the molding material is PA12, PA11, TPU, or PP powder. The determination of process parameters further includes: The injection volume of detailing agent and fusing agent is controlled to precisely regulate the edge sharpness and internal melting degree of the parts.

[0051] Layer thickness: usually fixed at 0.08mm.

[0052] Powder bed temperature: 160 to 170℃ for PA12.

[0053] Energy input: controlled by the power of the infrared lamps and the number of scans.

[0054] As another preferred option, the slicing and path planning in step S4 further includes the following optimization strategies: (1) Variable layer thickness slicing: For areas with gentle vertical changes in the module unit, a thicker layer thickness (e.g., 0.3mm) is used, while for areas with fine features (e.g., connection interfaces, surface textures) a thinner layer thickness (e.g., 0.1mm) is used, which improves the overall printing efficiency while ensuring the quality of key parts.

[0055] (2) Connection interface area enhancement strategy: When generating the printing path of the connection interface area, increase the number of contour circles in the area (e.g., from 3 circles to 5 circles), or adopt a full fill (100% fill density) strategy to enhance the mechanical strength and wear resistance of the interface.

[0056] (3) Optimization of molding direction: For long strip-shaped load-bearing components such as columns, vertical printing is preferred so that the interlayer bonding surface is perpendicular to the main force direction (axial pressure or tension) to obtain the best axial strength; for bending components such as beams, the placement method is selected according to the bending moment direction so that the interlayer direction is parallel to the neutral axis.

[0057] (4) Support structure optimization: For FDM process, easily peelable tree-shaped support is set for the suspended part of the connection interface (such as below the buckle hook). The contact surface between the support and the part adopts a small contact area (such as a contact point with a diameter of 0.2 mm) and a gap layer (Z-direction gap of 0.15 to 0.25 mm).

[0058] (5) Temperature control script embedding: embed speed and temperature control instructions for different areas in the G code, such as reducing speed and slightly increasing temperature when printing the connection interface to enhance interlayer bonding.

[0059] As another preferred option, the post-processing in step S6 is further refined according to different additive manufacturing processes: (1) FDM process post-processing flow: Remove supports: Use needle-nose pliers, tweezers, or a special support removal tool. Be especially careful with supports at the connection interface to avoid damaging the mating surfaces.

[0060] Surface cleaning: Use compressed air to blow away debris, and use a hot air gun to briefly blow away surface fraying.

[0061] Deburring: Use a utility knife or deburring knife to trim any excess material extruded from the edges of the connection interface.

[0062] Precision calibration: Use vernier calipers or go / no-go gauges to check the dimensions of the connection interface. For tenons that are too tight, use sandpaper (400 to 800 grit) to sand them evenly. For tenons that are too loose, apply a thin layer of UV resin and then cure it to compensate.

[0063] Surface strengthening (optional): Applying an epoxy resin coating or spraying a filler primer followed by sanding can eliminate laminations and obtain a smooth surface; or acetone vapor polishing can be used (ABS materials only).

[0064] (2) SLS post-processing flow: Powder cleaning: In a dedicated powder cleaning station, compressed air and soft brushes are used to remove unsintered powder from the surface and internal channels. Vibration or ultrasonic cleaning may be used if necessary.

[0065] Sandblasting: Glass microspheres or plastic abrasive are used for sandblasting under a pressure of 0.2 to 0.4 MPa to remove surface powder and obtain a uniform frosted texture.

[0066] Dyeing: If coloring is required, immerse the parts in an aqueous solution of acidic dye and heat to 80 to 95°C for 30 to 60 minutes. PA12 will absorb the dye and obtain a bright color.

[0067] Precision calibration: Use fine sandpaper to lightly grind the mating surfaces of sliding interfaces such as dovetail grooves until they slide smoothly.

[0068] Surface sealing (optional): Impregnation with polyurethane or epoxy resin sealant to improve surface hardness and water resistance.

[0069] (3) SLA process post-processing flow: Cleaning: Soak and agitate in isopropyl alcohol (IPA) or a special cleaning agent for 5 to 10 minutes. A two-step cleaning method (rough cleaning + fine cleaning) is even better.

[0070] Support removal: Remove the support after cleaning and before secondary curing. At this time, the resin has not been fully cured, so the support is easier to remove and causes less damage to the parts.

[0071] Secondary curing: Curing is performed in a UV curing chamber according to the wavelength and time required by the material.

[0072] Precision calibration: SLA parts have good dimensional stability and usually do not require extensive repairs. Only a very small number of tight-fitting surfaces need to be lightly sanded with fine sandpaper.

[0073] Surface treatment: It can be polished, painted, electroplated and other post-decorative treatments.

[0074] As another preferred option, the modular assembly in step S7 further includes the following specific operational instructions: (1) Before assembly, check whether the connection interfaces of each module unit are clean, free of burrs and deformation.

[0075] (2) For mortise and tenon joints, after aligning, apply force evenly along the insertion direction and push in. After hearing or feeling the "click" of the locking position, confirm that it is in place.

[0076] (3) For snap-on interfaces, align the snap with the slot and press until the cantilever springs back to lock.

[0077] (4) For the dovetail groove sliding interface, align the end of the convex rail with the groove opening and slide it along the groove to the predetermined position. After it is in place, there is usually a stop limit to prevent overtravel.

[0078] (5) If loosening occurs after assembly, a small amount of quick-drying glue or thread-locking agent can be used to fix it locally; if the fit is too tight, do not force it by knocking. The module should be removed to check the interface and make minor repairs.

[0079] (6) After assembly, check the diagonal dimensions and perpendicularity of the overall structure. If necessary, make fine adjustments at the leveling feet of the base module.

[0080] Compared with the prior art, the present invention has the following beneficial effects: 1. Short manufacturing cycle and low customization cost. This invention uses additive manufacturing technology to directly mold each module unit, eliminating the need for mold making and complex multi-stage machining. The cycle from design to finished product delivery can be shortened from 7 to 10 days in traditional processes to 2 to 3 days. Furthermore, small-batch customization avoids the high cost of mold amortization, resulting in an overall manufacturing cost reduction of over 50% compared to injection molding. This makes it particularly suitable for personalized display needs and rapid response in exhibition settings.

[0081] 2. High connection precision and efficient, reliable assembly. This invention integrates the functional connection interfaces of the display rack, such as mortise and tenon joints, snap fasteners, and dovetail grooves, with the module body through additive manufacturing, fundamentally avoiding positioning errors and assembly gaps caused by traditional secondary processing. By optimizing the printing parameters of the interface area, the mating gap can be stably controlled within the range of 0.1 to 0.3 mm, enabling rapid tool-free manual assembly between modules and maintaining reliable connection strength even after multiple disassemblies and reassemblies.

[0082] 3. Flexible structural design and significant weight reduction. The layer-by-layer additive manufacturing process easily achieves complex structures that are difficult to process using traditional methods, such as internal dot matrix filling, through-cable channels, and curved shapes. By employing differentiated filling density designs in load-bearing and non-load-bearing areas, this invention reduces the overall weight of the display rack by 30% to 50% compared to traditional steel-wood or aluminum alloy structures, while still meeting load-bearing requirements, thus facilitating transportation and site arrangement.

[0083] 4. Wide process adaptability and strong technical reproducibility. This invention systematically discloses specific parameter systems and post-processing specifications applicable to various additive manufacturing processes such as FDM, SLS, SLA, and MJF. Those skilled in the art can flexibly select process routes and implement them directly according to the actual size, strength, precision, and cost requirements of the display rack, without the need for extensive process exploration. It has good engineering universality and promotional value. Attached Figure Description

[0084] Figure 1 This is a flowchart illustrating the overall process flow of the rapid prototyping manufacturing process for the modular display rack of the present invention. Figure 2 A logic flowchart for the modular design of step S2; Figure 3 Decision flowchart for determining additive manufacturing process parameters in step S3; Figure 4 Flowchart of equipment operation for additive manufacturing step S5; Figure 5 This is a flowchart of the post-processing procedure in step S6; Figure 6 This is a flowchart of the assembly sequence for step S7, modular assembly. Detailed Implementation

[0085] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be described in detail below with reference to specific embodiments and flowcharts. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the scope of protection of the invention.

[0086] Example 1: Manufacturing small and medium-sized desktop display racks using FDM technology This embodiment uses a small to medium-sized desktop display stand for displaying consumer electronics products (such as mobile phones and tablets) as an example. The overall dimensions of the display stand are: height 600mm, width 800mm, and depth 400mm. The design requirements are: able to support 10kg of exhibits, simple and modern appearance, quick assembly and disassembly, and concealed internal wiring.

[0087] Step S1: Digital Modeling A 3D digital model of the display rack was created using SolidWorks 2023 software. The model includes: a rectangular frame structure consisting of four uprights, eight crossbeams (four long crossbeams connecting the front and rear uprights, and four short crossbeams connecting the left and right uprights), three layers of display panels, and four independent bases. The constraints of additive manufacturing processes were fully considered during the model creation process. (1) The column cross section is designed as a 30mm×30mm rectangle, with rounded corners R3 to improve stress distribution and print quality.

[0088] (2) The suspension angle of all suspended structures is controlled within 45°. Any excess will be automatically supported during slicing.

[0089] (3) The minimum wall thickness is designed to be 2mm to ensure printing reliability.

[0090] (4) The wall thickness at the connection interface is locally increased to 3mm to enhance strength.

[0091] (5) The crossbeam is designed with a through hole with a diameter of 6mm as a cable channel. The inner wall of the channel is smooth to facilitate cable threading.

[0092] After modeling is completed, export the model as a high-precision STL format file (chord height tolerance 0.01mm, angle tolerance 1°).

[0093] Step S2: Modular Decomposition Design Based on the effective printing size of the FDM equipment (in this embodiment, a Raise3DPro2Plus industrial-grade FDM printer with a printing area of ​​305mm×305mm×605mm is used), the overall model is divided into the following modular units: (1) Column module: There are four pieces in total, each with a height of 600mm. Since 600mm is within the Z-axis travel range (605mm) of the equipment, the column does not need to be segmented and is printed as a whole. The two ends of the column are designed with mortise and tenon joint structure: the bottom is a tenon structure with a root size of 25mm×25mm and a height of 15mm. The tenon gradually thins outward from the root, forming a 5° wedge-shaped guide slope on both sides. The top size of the tenon is 24mm×24mm. The top is a mortise and tenon structure with an inner cavity size of 25.2mm×25.2mm (leaving a 0.2mm fitting gap) and a depth of 16mm. The inner wall of the mortise and tenon has a locking step with a height of 1mm and a width of 2mm near the opening, which forms a self-locking with the shoulder of the tenon. The four sides of the column are provided with crossbeam installation interfaces: along the height direction, installation holes with a diameter of 8.2mm (leaving a 0.2mm gap) are opened at 100mm, 300mm and 500mm from the bottom, respectively, with a hole depth of 10mm. The interior of the column adopts a zoned filling strategy: within a 50mm range from both ends (including the connection interface area), a 60% filling density and honeycomb filling pattern are used; the middle 500mm section uses a 25% filling density and a straight filling pattern to achieve lightweighting.

[0094] (2) Crossbeam Module: There are eight in total, including four long crossbeams (front-to-back direction) with a length of 800mm and four short crossbeams (left-to-right direction) with a length of 400mm. Since 800mm exceeds the X / Y forming width of the equipment, each long crossbeam is divided into two 400mm sub-segments and connected by a threaded fastening structure in the middle. The crossbeam cross-section is designed to be 20mm×20mm, with cylindrical connectors at both ends, 8mm in diameter and 15mm in length, which are fitted with the mounting holes on the side of the column. A limiting step with a diameter of 12mm and a thickness of 2mm is provided at the root of the connector to prevent over-insertion. The crossbeam has a 6mm diameter through-cable channel inside, with flared ends at both ends for cable threading. For the middle connection structure of the long crossbeam, an M5 threaded hole is designed at each of the two sub-segments (the threaded bottom hole is directly formed in FDM printing, with a diameter of 4.2mm, and then tapped with a tap or a self-tapping screw).

[0095] (3) Display panel module: Three pieces in total, each measuring 800mm×400mm×5mm. Due to the overall size exceeding the equipment's dimensions, each panel is divided into two 400mm×400mm sub-panels, joined together via a tongue-and-groove joint. The panel's four edges are designed with a snap-lock structure: three snaps are evenly distributed along the long side of the panel, and two snaps are distributed along the short side. The snap-lock structure includes an elastic cantilever extending downwards from the panel edge (2.5mm thick, 8mm wide, 15mm long), with an outwardly protruding snap hook at the end of the cantilever (1.5mm protrusion). The upper surface of the crossbeam module has a corresponding snap groove (2mm deep, 8.2mm wide, with an inverted buckle on the inner side to engage with the hook). When the panel is pressed down, the cantilever bends elastically inwards, the hook enters the groove, the cantilever springs back, and the hook engages with the inverted buckle to lock. The panel surface is designed with an anti-slip texture (0.5mm high micro-bump array), which is directly formed during printing.

[0096] (4) Base module: There are four pieces in total, with dimensions of 80mm×80mm×20mm. The center of the upper surface is provided with a mortise (inner cavity 25.2mm×25.2mm, depth 16mm, with locking step) to mate with the tenon at the bottom of the column. The four corners of the bottom of the base are provided with M8 threaded holes (bottom hole diameter 6.8mm) for installing leveling pads.

[0097] (5) Decorative cover plate module: There are four pieces in total, which are used to cover the installation hole of the crossbeam connector. The size is 20mm×20mm×3mm. There are two small cylindrical buckles on the back, which can be inserted into the pre-reserved buckle holes of the crossbeam.

[0098] Step S3: Determining Additive Manufacturing Process Parameters This embodiment employs a fused deposition modeling (FDM) process. Considering both the functional requirements of the display rack (load-bearing structural components and aesthetic elements) and cost factors, PETG (polyethylene terephthalate-1,4-cyclohexanedimethyl ester) engineering plastic filaments were selected as the molding material. PETG combines the printability of PLA with the mechanical strength of ABS, while also exhibiting low moisture absorption and good interlayer adhesion. Specifically, eSUNPETG filaments with a diameter of 1.75mm ± 0.05mm were chosen.

[0099] The process parameters were determined as follows after optimization through orthogonal experiments:

[0100] Special Note: The full filling and 5-ring contour design of the connection interface area significantly enhance the strength and wear resistance of key parts such as tenons and buckles. It has been verified that the buckle insertion and removal life can be increased from about 20 times in conventional printing to more than 50 times.

[0101] The nozzle temperature is increased by 5°C in the interface area to reduce melt viscosity, enhance interlayer diffusion bonding, and increase Z-axis strength by approximately 15%.

[0102] The first layer of the heated bed is kept at a high temperature to ensure a flat bottom surface without warping, while subsequent layers are kept at a moderate temperature to prevent the material from softening and deforming due to prolonged high temperatures.

[0103] Step S4: Slicing and Path Planning Import the STL files of each module unit into the UltimakerCura 5.3 slicing software. Key operations in slicing: (1) Model placement optimization: Column module: placed vertically, with the Z-axis direction being the column height direction. This placement ensures that the interlayer is parallel to the horizontal plane, and the axial pressure borne by the column is perpendicular to the interlayer, making full use of the high compressive strength of FDM parts in the Z-direction (the Z-direction compressive strength of PETG is approximately 70% of its XY-direction tensile strength).

[0104] Horizontal beam module: Placed horizontally with the cylindrical surface of the connector facing upwards. A tree-like support is generated below the connector (support structure density 15%, support Z-axis gap 0.2mm).

[0105] Display panel module: Placed horizontally with the bottom facing down. Supports are automatically generated below the cantilevered portion of the panel clips.

[0106] Base module: Place horizontally with the bottom facing down.

[0107] (2) Dynamic floor height setting: For the column module, the overall layer height is set to 0.2mm, but the 50mm range at both ends (including the connection interface) is printed with a layer height of 0.1mm (achieving a smooth transition through the "Adaptive Layer Height" function). This strategy allows for higher surface quality and dimensional accuracy in critical mating areas without affecting overall printing efficiency.

[0108] (3) Enhanced connection interface area: In Cura, use the "PerModelSettings" function to cover areas such as tenons, mortises, and snaps with the following parameters: wall thickness 2.0 mm, infill density 100%, and print speed 35 mm / s. The slicing software will automatically identify these areas and apply the coverage parameters.

[0109] (4) Fine-grained control of supporting structure: A SupportBlocker is set below the beam connector to restrict the support to only be generated below the necessary cylindrical surface; a "tree-like support" is used below the snap-fit ​​cantilever, with the Z-axis gap between the top surface of the support and the model set to 0.2mm and the diameter of the support contact point to 0.6mm, which facilitates later removal.

[0110] (5) G-code post-processing: After slicing and generating G-code, a Python script is used to insert custom instructions into the code: when printing to the connection interface layer, an M104S250 command is sent to increase the nozzle temperature by 5°C, and the original temperature is restored after the layer is printed. The script also inserts a photo-trigger command after each layer is printed (for monitoring).

[0111] Step S5: Additive Manufacturing Preparation before printing: Dry the PETG filament in a constant temperature drying oven at 65°C for 4 hours (PETG has moderate hygroscopicity, and drying can effectively prevent bubbles and stringing during printing).

[0112] Clean the printing platform and apply PVP solid adhesive to enhance the adhesion of the first layer (PETG and PEI spring steel plate are too tightly bonded, so applying adhesive acts as a barrier to prevent damage to the base plate when disassembling parts).

[0113] Preheat the printer until the heated bed temperature stabilizes at 85°C before starting to print.

[0114] Printing process monitoring: During the first layer of printing, observe the uniformity and adhesion of the lines to confirm that there are no lifts or gaps.

[0115] Use the OctoPrint remote monitoring system to view the printing progress in real time, checking it every 30 minutes.

[0116] When printing to the connection interface area, confirm that the temperature automatically switches to 250℃ and the speed drops to 35mm / s.

[0117] For a column module with a height of 600mm, when printed to a height of approximately 500mm (total number of layers approximately 2500), the top stability was checked and no swaying or misalignment was observed.

[0118] Total printing time: approximately 11 hours per column module, approximately 4 to 6 hours per beam module, approximately 5 hours per display panel, and approximately 1.5 hours per base module. Two printers are used in parallel, and all modules are printed within 24 hours.

[0119] Step S6: Post-processing After printing, allow the heated bed to cool naturally to below 40°C (approximately 30 minutes) before removing the part. Post-processing is performed as follows: (1) Remove the supporting structure: Carefully remove the support material below the crossbeam connector and the snap-fit ​​cantilever using needle-nose pliers and tweezers. For areas where the support is in tight contact with the parts, gently cut the contact point with a utility knife before removing it. Pay special attention to the support below the tenon bevel and the snap-fit ​​hook to avoid damaging the precision mating surfaces.

[0120] (2) Surface cleaning: Remove surface debris with a soft brush. For small amounts of fraying, use a heat gun (set temperature 150℃) to blow away the debris for a short time (1-2 seconds). Clean the cable channels inside the beam with a 5mm diameter flexible shaft cleaning brush.

[0121] (3) Deburring and edge trimming: Use a deburring tool to smooth out any small excess material from the edges of the tenons and the cantilever edges of the clips. For the cylindrical surfaces of the beam connectors, lightly sand with 800-grit sandpaper to remove any roughness and make them smooth.

[0122] (4) Precision calibration and fitting: Use a digital vernier caliper (0.01mm accuracy) to check the critical dimensions of all tenons, mortises, connectors, and mounting holes.

[0123] For tenons that are too large (greater than 25.05mm), use 400-grit sandpaper to evenly sand all four sides, measuring after every few sanding passes, until the size falls within the range of 24.95-25.05mm.

[0124] For mounting holes that are too small (less than 8.15mm), manually ream the holes using an 8.2mm reamer.

[0125] Trial assembly of the column and base, and the column and beam, to check the tightness of the fit. The tenon and mortise should have a moderate insertion force (approximately 30-50N) and should not be loose after insertion. If too tight, lightly sand the side of the tenon; if too loose, apply a thin layer of 502 quick-drying adhesive to the side of the tenon, and after it dries completely, test assembly (the adhesive layer should thicken by approximately 0.02-0.05mm).

[0126] For the M5 threaded holes in the middle section of the long crossbeam, tap with an M5 tap to ensure that the screws can be screwed in smoothly.

[0127] (5) Surface strengthening treatment: This embodiment demonstrates the exterior components. A layer of matte clear varnish (acrylic spray paint) is sprayed onto the exposed surfaces of the display panel and pillars. Before spraying, the surface is lightly sanded with 600-grit sandpaper to increase adhesion. Two to three coats are applied, with a 15-minute interval between each coat. After spraying, the surface texture is largely eliminated, presenting a fine matte finish.

[0128] Step S7: Modular Assembly The assembly process is as follows (no tools required): (1) Place the four base modules on a flat table at the four corners of an 800mm×400mm rectangle.

[0129] (2) Take the column module and identify the bottom (tenon end) and top (mortise end). Align the bottom tenon of the column with the mortise of the base, apply vertical downward force to push it in, and confirm that it is in place after hearing a "click" sound and feeling the engagement.

[0130] (3) Insert the connector of the short crossbeam (400mm) into the mounting holes on the sides of the two adjacent columns to form the left and right side frames. Since there are connectors at both ends of the crossbeam, insert one end first and then the other end. The assembly can be completed by taking advantage of the slight elastic bending of the crossbeam.

[0131] (4) Insert the connector of the long crossbeam (800mm, consisting of two 400mm segments connected by M5 screws) into the mounting holes of the front and rear columns to complete the overall frame. Repeat steps (3) and (4) for the middle and upper crossbeams.

[0132] (5) After splicing the sub-boards of the display panel module with tongue and groove, place them on the crossbeam of the corresponding layer, align them with the buckle positions and apply pressure evenly. A continuous "click" sound indicates that all buckles are locked.

[0133] (6) Insert the decorative cover into the mounting hole on the outside of the crossbeam to cover the connector.

[0134] (7) If wiring is required, insert the cable through the pre-set hole in the base, and lead it out through the inside of the column and the cable channel of the crossbeam to the required location. The cable is hidden throughout.

[0135] (8) Check the overall structure: visually check the verticality of the column and measure the diagonal dimensions with a tape measure. If the error is within ±2mm, it is acceptable.

[0136] Example 1 Effect Verification

[0137] Example 2: Manufacturing high-strength large exhibition display racks using SLS technology This embodiment uses a brand display main stand for a large international exhibition as an example. The overall dimensions of the stand are: height 2400mm, width 3600mm, and depth 900mm. The design requirements are: ultra-high strength (to suspend a large screen display), modern streamlined shape, reusable after multiple disassemblies and relocations, and high-end appearance.

[0138] Step S1: Digital Modeling Rhino7 software was used to model complex curved surfaces, constructing the overall 3D digital model of the display stand. The display stand adopts an organic streamlined design: the columns are slightly curved and tapered inwards, the beams are variable cross-section I-beams, and the display back panel is a hyperboloid shape. The following functional features were added to the model: (1) The internal design of the column is a truss lattice structure (body-centered cubic BCC lattice, rod diameter 3mm, unit cell size 15mm), which greatly reduces weight while ensuring overall rigidity.

[0139] (2) The beam is designed with a closed cavity to accommodate the LED light strip and power cord.

[0140] (3) The connection node between the column and the beam is designed as a three-dimensional interlocking structure to withstand multi-directional loads.

[0141] (4) The base is designed as a hidden counterweight compartment, which can be filled with steel sand to increase stability.

[0142] Step S2: Modular Decomposition Design Based on the effective forming dimensions of the SLS equipment (this embodiment uses the EOSP396 industrial-grade SLS equipment, with a forming cylinder size of 340mm × 340mm × 600mm), the display stand is divided into the following modular units: (1) Column Module: There are six columns in total, each with a total height of 2400mm. Each column is divided into four sub-modules (600mm each), which are connected by built-in mortise and tenon joints. The interior of each column is filled with BCC dot matrix, and the outer shell wall thickness is 4mm. The two ends of the column are designed with: male interface - protruding cross-shaped tenon (40mm long, cross rib plate thickness 6mm), the tenon end is designed with a wedge-shaped guide slope; female interface - concave cross-shaped tenon groove (42mm deep, groove width 6.2mm with a 0.2mm gap), the bottom of the groove is equipped with an elastic locking tongue (2mm thick cantilever structure). The outer side of the column is opened with a continuous dovetail groove along the height direction (dovetail angle 60°, groove depth 8mm, groove width 15mm) for connecting the crossbeam module.

[0143] (2) Crossbeam Modules: Eighteen in total, ranging in length from 900mm to 1800mm. The crossbeam has an I-shaped variable cross-section, with dovetail rails (50mm long, matching the dovetail groove with a 0.15mm clearance) at both ends to mate with the dovetail grooves of the columns. The crossbeam has a 20mm×30mm rectangular cable cavity with a wall thickness of 3mm inside. The outer surface of the crossbeam has T-slots for installing display hooks or LED strip clips.

[0144] (3) Connection node module: a total of twelve pieces, used for the reinforcement connection at the intersection of the column and the beam. It is designed as a three-dimensional interlocking structure, including dovetail rails in three directions, which can form a spatial interlock with the dovetail grooves / rails of the column and the beam.

[0145] (4) Curved display back panel module: six pieces in total, each measuring approximately 800mm × 1200mm, with a double-curved shape and a thickness of 4mm. The back of the back panel is designed with honeycomb-shaped reinforcing ribs (rib height 8mm, rib thickness 2.5mm, honeycomb hexagonal side length 20mm). The edges of the back panel are designed with snap-on interfaces, which can be quickly snapped into the T-slots of the crossbeams.

[0146] (5) Base module: six pieces in total, with dimensions of 300mm×300mm×80mm. The internal design includes a counterweight cavity of 150mm×150mm×50mm, and the top is equipped with an openable cover plate. The upper surface is provided with a cross-shaped tenon that mates with the female interface at the bottom of the column. The four corners of the bottom are provided with M12 leveling foot cup mounting screw holes.

[0147] Step S3: Determining Additive Manufacturing Process Parameters The selective laser sintering process is adopted, and the material selected is glass fiber reinforced PA12 composite powder (EOSPA3200GF). This material contains 30% chopped glass fiber, which has extremely high stiffness and dimensional stability, and a heat distortion temperature as high as 176℃, making it very suitable for large load-bearing structural components.

[0148] Specific process parameters were determined through optimization using the equipment and materials database:

[0149] Step S4: Slicing and Path Planning Data processing was performed using EOSRP-Tools and Magics software. (1) Three-dimensional nested arrangement: The module units are arranged in a three-dimensional tight arrangement in the molding cylinder to ensure that the distance between each part is ≥5mm to facilitate powder removal. In this embodiment, all six column modules, twelve crossbeam modules, six connecting node modules and some back plate modules are arranged in one cylinder, with a filling rate of about 12% (powder volume ratio).

[0150] (2) Shrinkage compensation: Based on the measured shrinkage rate of PA3200GF (2.8% in X / Y direction and 3.2% in Z direction), anisotropic scaling compensation (1.028 times in X / Y direction and 1.032 times in Z direction) was performed on the model before slicing.

[0151] (3) Scanning strategy optimization: For precision mating surfaces such as dovetail grooves and dovetail convex rails, the "contour priority + fine scanning" mode is activated. The contour is first scanned at a lower speed and higher power to ensure that the edges are clear and sharp.

[0152] For the interior of the BCC dot matrix, enable the "Quick Fill" mode to improve efficiency.

[0153] For the upper and lower flange areas of the I-beam, enable the "Strengthen Edges" function to increase the number of contour scans (from the default 2 scans to 4 scans).

[0154] Step S5: Additive Manufacturing PA3200GF powder was added to the equipment, and the powder was pre-dried at 80°C for 4 hours.

[0155] Once printing is started, the equipment automatically completes the powder spreading, preheating, and laser sintering cycle.

[0156] The entire molding process takes approximately 42 hours (including preheating and cooling stages).

[0157] During the printing process, parameters such as temperature, laser power, and oxygen content are recorded by the equipment monitoring system, and all parameters fluctuate within the set range.

[0158] Step S6: Post-processing (1) Powder Removal: After the molding cylinder cools to room temperature, the powder block is removed and transferred to a dedicated powder removal station. Compressed air (pressure 0.3MPa) and an antistatic soft brush are used to remove unsintered powder from the surface and internal channels of the parts. For the interior of the BCC lattice, vibration-assisted powder removal is used—the parts are placed on a vibration table and low-frequency vibration is used to cause the powder to flow out from the lattice pores. The powder removal process takes about 4 hours.

[0159] (2) Sandblasting: Place the cleaned parts into the sandblasting machine, use 180-mesh glass beads, sandblasting pressure of 0.3MPa, nozzle distance of about 200mm, and move evenly for sandblasting for about 2-3 minutes. After sandblasting, the surface of the parts has a uniform and delicate frosted texture and the color is light gray.

[0160] (3) Stress relief through heat treatment: Place the sandblasted parts in an oven and keep them at 160°C for 2 hours, then slowly cool them in the oven. This step can release the residual thermal stress during the SLS molding process and improve dimensional stability.

[0161] (4) Precision machining of mating surfaces: Use fine sandpaper (600 grit) to lightly polish the mating surfaces of the dovetail groove and the dovetail convex rail along the sliding direction to remove the micro-roughness caused by sandblasting, so that the mating clearance reaches the design value of 0.15-0.25mm. Use a go / no-go gauge to check the dimensions of the dovetail groove.

[0162] (5) Dyeing (optional): This embodiment requires the display stand to be the brand color (dark gray), using an acid dye dyeing process. Immerse the parts in a deionized aqueous solution containing dark gray acid dye (dye concentration 5g / L, liquor ratio 1:20), heat to 90℃ and hold for 40 minutes, stirring appropriately during the process. After removal, rinse with clean water and air dry. The color is uniform after dyeing, and the color fastness to rubbing reaches grade 4-5.

[0163] (6) Surface sealing (optional): For the display back panel module, a layer of transparent matte water-based polyurethane paint is sprayed to enhance the surface's stain resistance.

[0164] Step S7: Modular Assembly Due to the large size of the display stand, assembly requires two people and requires virtually no tools (only an Allen wrench is needed to adjust the feet). (1) Lay the six base modules on the ground according to the design position, use a laser level to ensure that the bases are on the same horizontal plane, and make fine adjustments by adjusting the leveling cups.

[0165] (2) Column assembly: Connect the four sub-modules of each column through cross-shaped tenon joints. When inserting the joints, align them with the cross direction and push them in until the elastic locking tongue engages and locks. After all six columns are assembled, insert them into the cross-shaped tenons of the corresponding bases for fixation.

[0166] (3) Install the connection node module: Align the dovetail rail of the connection node module with the predetermined position on the column and slide it into the stop position along the dovetail groove.

[0167] (4) Install the crossbeam module: Align the dovetail rails at both ends of the crossbeam with the dovetail grooves of the column or connecting node, and slide them in from top to bottom or push them in from the side (depending on the installation direction). After the crossbeams are installed, a stable spatial frame is formed.

[0168] (5) Install the display back panel module: Align the clips of the curved back panel with the T-slots on the crossbeam and press them in. The seams between the back panels are designed with decorative strips (also SLS printed), which cover the gaps after they are inserted.

[0169] (6) Wiring: The LED light strip is pasted into the cable cavity of the crossbeam, and the power cord is gathered through the internal channel between the crossbeam and the column to the base counterweight compartment and connected to the power controller.

[0170] (7) Check all connection nodes to ensure that the dovetail groove fits tightly without shaking. If necessary, use a small amount of screw glue to reinforce the hidden parts.

[0171] Example 2 Effect Verification

[0172] Example 3: Manufacturing a high-precision display module using SLA technology This embodiment uses a small display module for high-end jewelry display as an example. The overall dimensions of the display module are: height 180mm, width 120mm, and depth 120mm. The design requirements are: ultra-high surface finish (mirror effect), fine texture details, and a precision rotating display platform.

[0173] Step S1: Digital Modeling The display module was created using high-precision digital sculpting with ZBrush software. The model includes intricate relief patterns (minimum detail 0.2mm), precision bearing housing holes for the rotating display stand, and concealed interfaces for connecting to an external power source.

[0174] Step S2: Modular Decomposition Design The model is divided into: a base (including a rotating motor mounting cavity), a rotating platform (including a bearing mounting shaft), and a decorative outer shell (including embossed texture). The connection interface adopts a precision dovetail sliding fit structure (dovetail angle 60°, fitting gap design 0.05-0.08mm) and a magnetic interface.

[0175] Step S3: Determining Additive Manufacturing Process Parameters The process employs SLA technology, using SomosImagine8000 photosensitive resin, which possesses ABS-like mechanical properties and excellent detail rendering capabilities.

[0176]

[0177] Steps S4 to S5: Slicing and Shaping Position the model at the optimal angle (relief side up to minimize the impact of supports on details), and slice to generate supports. Printing time is approximately 5 hours.

[0178] Step S6: Post-processing Clean twice with isopropyl alcohol (3 minutes for rough cleaning + 3 minutes for fine cleaning).

[0179] Carefully remove the support.

[0180] Curing in a UV curing chamber for 40 minutes.

[0181] Wet sand the surface with 2000-grit sandpaper, then mechanically polish it with polishing compound until it achieves a mirror finish.

[0182] The mating surfaces of the dovetail groove are precision ground using polishing paste and corresponding fixtures to achieve a gap of 0.05mm.

[0183] Step S7: Assembly The micro motor is installed in the base cavity, the rotating platform is connected to the base through bearings, and the decorative shell slides in through the dovetail groove and is magnetically fixed.

[0184] Example 3 Effect Verification Surface roughness: Ra≤0.05μm after polishing (mirror finish).

[0185] Relief detail reproduction: 0.2mm line width is clearly discernible.

[0186] Radial runout of the rotary table: ≤0.03mm.

[0187] Example 4: Manufacturing a multi-functional display rack using a multi-material combination process This embodiment demonstrates the flexibility of the process of the present invention, that is, different module units of the same display rack can use different additive manufacturing processes and materials to achieve the optimal configuration of performance and cost.

[0188] Display rack requirements: A display rack for a cosmetics counter, including a high-strength main frame, a high-transparency display cover, flexible cushioning pads, and a decorative logo sign.

[0189] Process allocation plan:

[0190] Assembly method: Each module is still assembled through a standardized connection interface with a unified design (in this embodiment, a threaded fastening structure is used in conjunction with metal inserts). The metal inserts (such as M3 copper nuts) are embedded during the FDM printing process (a pause layer is designed, and printing continues after the inserts are manually inserted), achieving a secure threaded connection.

[0191] Comparison of experimental and performance data To verify the technical effects of the present invention, the following comparative experiments were conducted: Experiment 1: Manufacturing Cycle Comparison

[0192] Experiment 2: Customization Cost Comparison (Taking 100 sets of small and medium-sized display stands as an example)

[0193] Note: This invention has a significant cost advantage when producing small batches (<500 pieces) and eliminates the need for mold waiting time.

[0194] Experiment 3: Connection Interface Strength Test Test sample: mortise and tenon joint specimen printed by FDM on PETG material (tenon 25mm×25mm×15mm, gap 0.2mm).

[0195] Test method: Tensile test using a universal testing machine, with a loading speed of 5 mm / min.

[0196]

Claims

1. A rapid prototyping manufacturing process for a modular display rack, characterized in that, Includes the following steps: Step S1: Digital Modeling – Based on the functional and structural requirements of the display rack, a three-dimensional digital model of the display rack is created using computer-aided design software. Step S2: Modular Decomposition Design - The overall three-dimensional digital model is modularly decomposed, and the display rack is divided into several standardized module units. Each module unit is designed with a standardized connection interface. The connection interface is selected from at least one of the following structures: mortise and tenon joint structure, snap-lock structure, dovetail groove sliding fit structure or threaded fastening structure. Step S3: Determine additive manufacturing process parameters—Based on the functional requirements and mechanical performance requirements of each module unit, select the appropriate additive manufacturing process type and molding material, and determine the corresponding process parameters; Step S4: Slicing and Path Planning - Using slicing software, the 3D digital model of each module unit is sliced, the 3D model is converted into layer-by-layer 2D contour data, and the printing path and support structure scheme are generated. Step S5: Additive manufacturing forming—Based on the process parameters determined in step S3 and the printing path generated in step S4, additive manufacturing equipment is used to process each module unit layer by layer, wherein the module unit and its connection interface are directly formed in an integrated manner; Step S6: Post-processing—Post-processing of each module unit after molding, including removal of support structure, surface cleaning, deburring, precision calibration and / or surface strengthening treatment; Step S7: Modular assembly – After post-processing, the modular units are assembled through their connection interfaces to form a complete modular display rack.

2. The process according to claim 1, characterized in that, In step S2, the maximum external dimensions of the module unit do not exceed the effective forming area of ​​the additive manufacturing equipment, and the connection interfaces between the module units adopt uniform standardized interface dimensions and tolerances.

3. The process according to claim 1, characterized in that, In step S2, the connection interface adopts a mortise and tenon joint structure, which includes: a tenon structure set at the end of a module unit, the root of the tenon being connected to the module unit body, and the head of the tenon having a wedge-shaped guide slope; and a mortise and tenon structure set at the end of another module unit that cooperates with the module unit, the inner wall of the mortise and tenon having a locking step that cooperates with the wedge-shaped guide slope.

4. The process according to claim 1, characterized in that, In step S3, the additive manufacturing process is selected from at least one of fused deposition modeling, selective laser sintering, stereolithography, or multi-jet melting.

5. The process according to claim 4, characterized in that, When using fused deposition modeling (FDM), the molding material is selected from at least one of PLA, ABS, PETG, nylon, or carbon fiber reinforced composite filaments; the process parameters include: nozzle temperature of 190°C to 300°C, heated bed temperature of 60°C to 100°C, printing speed of 30 to 80 mm / s, layer thickness of 0.1 to 0.3 mm, and filler density of 20% to 80%.

6. The process according to claim 4, characterized in that, When selective laser sintering is used, the molding material is nylon powder or TPU powder; the process parameters include: laser power of 30 to 60W, scanning speed of 5 to 15m / s, layer thickness of 0.1 to 0.15mm, and powder bed preheating temperature of 160 to 180℃.

7. The process according to claim 1, characterized in that, In step S5, the connection interface is integrally printed with the module unit body during the additive manufacturing process, without the need for subsequent secondary processing.

8. The process according to claim 1, characterized in that, In step S6, the post-processing also includes precision grinding or fitting of the mating surfaces of the connection interface to control the interface mating gap within the range of 0.1 to 0.3 mm.

9. The process according to claim 1, characterized in that, The module unit in step S2 also includes an internal channel for accommodating the cable, which is integrally formed in a hollow structure during the additive manufacturing process in step S5.

10. The process according to any one of claims 1 to 9, characterized in that, The slicing and path planning in step S4 includes: using a higher filling density and / or a smaller layer thickness for the connection interface area than for the main body area, and optimizing the forming direction of each module unit to match the stress direction with the interlayer bonding direction.

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