3D Freeform Material Deposition for Smooth, Fast Additive Manufacturing
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Solution Overview
Problem
Existing rapid prototyping techniques, such as SLM, SLA, FDM, and 3DP, face challenges with poor surface finish and slow build-up rates due to the layer-by-layer construction methodology and point-scanning methods, which result in stairs-like surface features and increased equipment costs.
Innovation Solution
The Flexible 3D Freeform technique dispenses solidifiable material along tangential directions of the 3D article, using a dispensing head with multiple degrees of freedom and adjustable width, thickness, and flow speed to eliminate layered surface features and enhance surface finish, while increasing fabrication speed through ribbon-shaped material dispensing and differential molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If layer-by-layer construction methodology is used, then material can be deposited systematically, but surface finish deteriorates due to inevitable layered (stairs-like) surface features
Solution Approach 1:
The patent applies continuous curved trajectories instead of horizontal layer-by-layer construction. The dispensing head moves along smooth curved paths that follow the contour of the 3D object, eliminating the stepped surface features inherent in layer-based methods and achieving superior surface finish without post-processing.
Solution Approach 2:
The patent employs a dispensing head with multiple degrees of freedom that can dynamically adjust its position, orientation, and dispensing parameters in real-time. This dynamic capability allows the system to adapt to complex 3D geometries and maintain optimal deposition angles throughout the fabrication process.
2Manufacturing precision
If point scanning method is used for material joining, then precise material placement is achieved, but build-up rate decreases due to slow scanning speed
Solution Approach 1:
The patent transitions from discrete point scanning to continuous material deposition along curved trajectories. The dispensing head continuously deposits material while moving along optimized paths, eliminating the stop-and-go nature of point scanning and significantly increasing the build-up rate while maintaining placement precision through controlled motion.
3Ease of manufacture
If fixed orifice size nozzle is used in FDM, then material flow is controlled, but dispensing speed cannot be increased significantly and filament width variation is limited
Solution Approach 1:
The patent replaces the fixed orifice nozzle with a variable geometry dispensing head that can dynamically adjust its opening size and shape. This allows real-time modification of material flow rate and deposited filament width according to the local geometry requirements, enabling both high-speed dispensing and precise dimensional control.
Solution Approach 2:
The patent implements variable dispensing parameters including adjustable flow rate, variable dispensing speed, and dynamic orifice size modification. These parameter changes allow the system to optimize material deposition for different sections of the 3D object, increasing overall dispensing speed while maintaining dimensional accuracy.
4Manufacturing precision
If SLM technique with small focal spot is used, then edge definition is improved, but equipment cost increases due to skin-core strategy requiring multiple laser focal spots
Solution Approach 1:
The patent uses a single dispensing head that copies the desired surface geometry through controlled motion along curved trajectories. Instead of using multiple laser focal spots or complex optical systems to achieve different spot sizes, the system replicates the target shape through programmed motion paths, simplifying the equipment while maintaining precision.
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 approach significantly improves surface finish and build-up speed by eliminating stairs-like features and allowing for flexible, curved trajectories, reducing the need for post-machining and increasing material deposition rates.
Implementation Method 1
dispensing a solidifiable material in a fluid state from a dispensing head onto a base member to build up the material, which solidifies under preset ambient conditions
Implementation Method 2
dispensing a solidifiable material in a fluid state from a dispensing head onto a base member to build up the material, which solidifies under preset ambient conditions
Data Source
AI summary
This invention relates to processes and systems of rapid prototyping and production. Its features includes flexible material deposition along tangential directions of surfaces of a part to be made, thereby eliminating stair-shape surface due to uniform horizontal layer deposition, increasing width of material deposition to increase build up rate, applying the principles of traditional forming/joining processes, such as casting, fusion welding, plastic extrusion and injection molding in the fabrication process so that various industrial materials can be processed, applying comparatively low cost heating sources, such as induction heating and arc-heating. Additional features include varying width and size of material deposition in accordance with geometry to be formed and applying a differential molding means for improved shape formation and surface finishing.