3D Build Surface Smoothing Using Temporary Flow Passages
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Solution Overview
Problem
Build objects produced by additive manufacturing methods, such as 3D printing, often have relatively rough surfaces that are difficult to smooth efficiently, especially when complex shapes prevent mechanical polishing or other post-processing methods from being effective.
Innovation Solution
Incorporating a flow passage forming part during the additive manufacturing process to cover areas requiring smoothing, followed by fluid polishing with a polishing liquid that is then removed, allowing for efficient surface smoothing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If additive manufacturing is used to build objects, then manufacturing capability and design freedom are improved, but surface roughness increases making polishing difficult
Solution Approach 1:
The flow passage forming part is built integrally with the build object during the additive manufacturing process, creating a built-in polishing channel before the object is completed. This preliminary structure enables subsequent fluid polishing without requiring separate mechanical polishing steps, thus resolving the contradiction between manufacturing capability and surface finish quality
2Manufacturing precision
If mechanical polishing is used to smooth surfaces, then surface roughness is improved, but complex shapes become difficult to process
Solution Approach 1:
The patent replaces mechanical polishing methods with fluid polishing using a polishing liquid that flows through the flow passage forming part. This substitution eliminates the need for complex mechanical polishing equipment and processes, allowing efficient surface smoothing even for objects with complex geometries that would be difficult to access with mechanical tools
3Manufacturing precision
If flow passage forming part is added during building, then surface polishing capability is improved, but manufacturing process complexity increases
Solution Approach 1:
The flow passage forming part is merged with the build object as an integral component during the additive manufacturing process. Instead of adding a separate polishing device, the flow passage is built into the object itself, combining the structural function with the polishing function in a single integrated structure, thus minimizing additional process complexity
4Manufacturing precision
If flow passage forming part is removed after polishing, then surface quality is improved, but additional removal process is required
Solution Approach 1:
The flow passage forming part is designed as a temporary structure that is intentionally removed after serving its polishing function. The removal process is integrated into the manufacturing workflow, and the flow passage structure is optimized for easy separation from the final build object, minimizing the time and effort required for removal while ensuring high surface quality
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
The method effectively smooths the surface of build objects by using fluid polishing, achieving a polished finish without the limitations of mechanical methods.
Implementation Method 1
by passing polishing fluid through a flow passage between the build object and the flow passage forming part, performing fluid polishing a portion, which contacts the flow passage, of the build object
Data Source
AI summary
A build method for forming a three-dimensional build object includes: building the build object by additive manufacturing, disposing a flow passage forming part such that the flow passage forming part faces at least a part of a polishing target surface of the build object, by passing polishing fluid through a flow passage between the build object and the flow passage forming part, performing fluid polishing a portion, which contacts the flow passage, of the build object; and disassembling of removing the flow passage forming part. It is possible to efficiently smooth surface roughness of a build object built by additive manufacturing (AM) method in which a 3D printer is used, for example.