3D Forming Apparatus Underlying Layer Suppresses Bending
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Solution Overview
Problem
Existing three-dimensional forming methods using fused deposition modeling (FDM) often result in bending of the formed object due to thermal contraction, which compromises dimensional accuracy, and require larger apparatus to manage temperature adjustments.
Innovation Solution
A method involving a three-dimensional forming apparatus with a forming head and cutting head that forms molten material into layers on an underlying layer portion, securing the material block to prevent deformation, and using a flat screw to maintain uniform material composition and reduce apparatus size, thereby suppressing bending without temperature adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the temperature of the forming table is adjusted to suppress bending, then dimensional accuracy is improved, but the size of the three-dimensional forming apparatus increases
Solution Approach 1:
The patent applies preliminary action by forming an underlying layer portion before depositing the molten material layers. This underlying layer serves as a preparatory structure that prevents bending during the subsequent layer formation process, eliminating the need for temperature adjustment of the forming table and avoiding the requirement for a larger apparatus.
Solution Approach 2:
The underlying layer portion acts as an intermediary element between the forming table and the molten material layers. It mediates the thermal and mechanical stresses during solidification, preventing direct contact between the forming table and the molten material, thereby suppressing bending without requiring temperature control of the forming table.
2Ease of manufacture
If the molten material is formed directly on the forming table, then manufacturing simplicity is improved, but bending occurs due to heat loss
Solution Approach 1:
The underlying layer portion is formed as a preliminary structure before the molten material is deposited. This pre-formed layer provides thermal insulation and structural support, preventing excessive heat loss from the forming table while maintaining manufacturing simplicity.
Solution Approach 2:
The underlying layer portion serves as an intermediary barrier between the forming table and the molten material. It mediates heat transfer to prevent direct thermal contact that would cause bending, while allowing the manufacturing process to remain simple and direct.
3Ease of operation
If the material block is not secured to the forming table, then ease of operation is improved, but deformation occurs during forming
Solution Approach 1:
The material block is secured to the forming table as a preliminary action before the forming process begins. This pre-securing prevents deformation during the subsequent layer formation, while the suction mechanism maintains ease of operation through automatic securing without manual intervention.
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 suppresses bending and maintains dimensional accuracy by enhancing welding strength between layers and ensuring uniform material composition, allowing for the fabrication of larger objects with a more compact apparatus.
Implementation Method 1
a three-dimensional forming apparatus using a fused deposition modeling (FDM) method
Implementation Method 2
securing the material block to prevent deformation
Data Source
AI summary
A method of manufacturing a three-dimensional formed object includes cutting a material block so as to fabricate a bottom portion that includes an upwardly projecting underlying layer portion. The method also includes forming a molten material into a single layer or a plurality of layers on a top of the underlying layer portion so as to fabricate a first layer portion in contact with the underlying layer portion.