3D Lamination Bead Cutting for High-Precision Shaping
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Solution Overview
Problem
Existing three-dimensional laminating and shaping technologies face challenges in achieving high precision without requiring finishing processing, particularly due to complexities in cutting side surfaces based on object shape, which prolongs processing time.
Innovation Solution
A three-dimensional laminating and shaping apparatus that includes a material ejector, a light beam irradiator, and a cutter, controlled by a controller, which adjusts the ejection and cutting of beads to reduce surface roughness and improve precision by cutting the upper surface of the beads to dimensions smaller than the laminating height, allowing for high-efficiency and high-precision shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If side surface cutting is performed based on object shape, then shaping precision is improved, but processing time is prolonged
Solution Approach 1:
The invention performs preliminary cutting of the upper surface of each bead during the laminating process itself, before the complete object is formed. By cutting the upper surface of beads to dimensions smaller than the laminating height during layer formation, the need for subsequent side surface cutting is eliminated, thus achieving high shaping precision without prolonging overall processing time
Solution Approach 2:
The invention divides the shaping process into discrete bead-level operations. Each bead's upper surface is independently cut to the required dimensions during its formation, transforming the continuous side surface cutting problem into discrete, manageable segments that are processed in parallel with the laminating workflow
2Manufacturing precision
If finishing processing is performed, then shaping precision is improved, but productivity is reduced
Solution Approach 1:
The invention merges the cutting operation with the laminating process by performing bead upper surface cutting immediately after bead formation and before the next bead is deposited. This integration eliminates the need for separate finishing processing steps, thereby maintaining high shaping precision while improving productivity through process consolidation
Solution Approach 2:
The cutting operation continues continuously during the laminating process without interrupting the overall workflow. Material ejection, light beam irradiation, and bead cutting occur in continuous sequence, ensuring that the useful action of shaping is maintained throughout the process without idle finishing operations
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 enables high-precision shaping without finishing processing, reducing surface roughness by up to 1/10 and shortening shaping time while maintaining high efficiency, even with complex shapes and materials having high light beam reflectance.
Implementation Method 1
a light beam irradiator 102 that irradiates the ejected material 130 with a light beam 140
Implementation Method 2
the material 130 irradiated with the light beam 140 is melted and solidified
Implementation Method 3
a cutter 103 that cuts a bead 160 formed when the material 130 irradiated with the light beam 140 is melted and solidified
Data Source
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AI summary
The shaping precision is improved without performing finishing processing. A three-dimensional laminating and shaping apparatus includes a material ejector that ejects a material of a three-dimensional laminated and shaped object onto a shaping table on which the three-dimensional laminated and shaped object is shaped, a light beam irradiator that irradiates the ejected material with a light beam, a cutter that cuts a bead formed when the material irradiated with the light beam is melted and solidified, and a controller that controls ejection of the material by the material ejector, irradiation with the light beam by the light beam irradiator, and cutting of the bead by the cutter. The cutter cuts an upper surface of the bead by a dimension which is smaller than a laminating height and is 1/2 or less of a bead thickness.