3D Freeform Deposition With Tangential Paths for Smooth Fast Builds
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rapid prototyping methods, such as SLM and FDM, face challenges with poor surface finish and slow build-up rates due to the layer-by-layer construction and point-scanning techniques, leading to significant post-machining costs and limited speed improvements.
Innovation Solution
The Flexible 3D Freeform technique dispenses solidifiable materials along tangential directions, using a dispensing head with multiple degrees of freedom and adjustable width, thickness, and flow speed to eliminate layered surface features and enhance fabrication speed, while differential molding ensures improved surface finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If layer-by-layer construction methodology is used, then material build-up is achieved, but layered surface features are created resulting in poor surface finish
Solution Approach 1:
The patent applies preliminary action by pre-heating the build platform and materials to optimal temperatures before the actual deposition process begins. This preparation ensures that materials are ready for immediate bonding upon contact, eliminating delays and maintaining continuous build operations without interruption for temperature stabilization, thereby improving both surface finish quality and build-up rate.
Solution Approach 2:
The patent implements dynamics by using a multi-axis robotic system with dynamic motion control that adjusts deposition speed, layer thickness, and heating parameters in real-time based on the complex 3D geometry being built. This dynamic adaptation allows the system to maintain optimal surface finish quality while maximizing build speed across varying surface curvatures and orientations.
2Reliability
If point scanning joining is used, then material joining is achieved, but build-up rate is slow
Solution Approach 1:
The patent applies continuity of useful action by implementing a continuous material deposition system where materials are extruded or sprayed in an unbroken stream rather than being deposited point-by-point. The robotic end effector maintains continuous contact with the build surface, ensuring uninterrupted material joining and bonding while significantly increasing the build-up rate compared to discrete point scanning methods.
Solution Approach 2:
The patent merges multiple functions into a single integrated robotic end effector that combines material deposition, heating, and bonding operations. This consolidation allows all joining actions to occur simultaneously in one continuous motion, eliminating the sequential point-by-point operations of traditional scanning methods and thereby大幅提高 build-up rate while maintaining reliable material joining.
3Manufacturing precision
If combined operation of layer dispensing and point-scanning joining is used, then material build-up is achieved, but process speed is slowed down
Solution Approach 1:
The patent applies preliminary action by pre-heating both the build platform and incoming materials to optimal bonding temperatures before deposition begins. This advance preparation eliminates the need for slow, sequential heating during the build process, allowing rapid layer construction at high process speeds while maintaining precise layer formation and strong inter-layer bonding.
Solution Approach 2:
The patent implements continuity of useful action by performing material dispensing and joining operations in a single continuous robotic motion without interruption. The system maintains constant deposition and bonding actions throughout the layer construction process, eliminating the stop-start nature of combined layer dispensing and point-scanning operations, thereby dramatically increasing process speed while preserving manufacturing precision.
4Strength
If SLM technique with laser melting is used, then metal parts are made, but surface finish is poor requiring significant post-machining cost
Solution Approach 1:
The patent applies parameter changes by systematically optimizing deposition parameters including material temperature, build platform temperature, deposition speed, and layer thickness to achieve superior surface finish quality. By carefully controlling these parameters, the system produces metal parts with smooth surfaces that meet or exceed required tolerances directly from the build process, eliminating or minimizing the need for expensive post-machining operations while maintaining part strength.
5Ease of manufacture
If FDM technique with fixed nozzle orifice is used, then material dispensing is achieved, but dispensing speed cannot be increased significantly
Solution Approach 1:
The patent implements dynamics by replacing the fixed nozzle orifice with a dynamically adjustable deposition system that can vary material flow rate and deposition parameters in real-time. The robotic system adjusts dispensing speed, material extrusion rate, and layer parameters adaptively based on the build geometry and required surface quality, enabling significantly increased dispensing speeds while maintaining ease of manufacture and part 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
This approach significantly improves surface finish and increases build-up speed by eliminating stairs-like features and allowing for adaptive material deposition based on local geometry, reducing post-processing costs and enhancing the efficiency of the fabrication process.
Implementation Method 1
dispensing the solidifiable material along the tangential directions of the surface of the 3D article to be fabricated so that the layered surface feature in existing rapid prototyping processes is eliminated
Implementation Method 2
materials which solidifies under preset ambient conditions, in a basically continuous fashion according to a predetermined relative movement sequence between the material dispensing head and the base
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.