3D Model Fabrication via Selective Machining
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Solution Overview
Problem
Existing three-dimensional modeling processes face challenges such as slow deposition rates, material wastage, and complex machining requirements, which hinder rapid and cost-effective production of complex models with smooth surface finishes.
Innovation Solution
A method and apparatus for depositing both model and sacrificial materials at rapid rates, forming channels and grooves in the build layer, and removing selected areas to create a smooth, vertical surface finish, using a combination of rapid deposition and machining techniques to facilitate high-speed fabrication of composite models with a smooth surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rapid deposition techniques are used to increase production speed, then productivity improves, but surface finish quality deteriorates
Solution Approach 1:
The process is segmented into distinct stages: rapid deposition phase followed by selective machining phase. Each stage optimizes for its specific purpose - deposition speed during material placement, and surface quality during selective removal and finishing operations.
Solution Approach 2:
Material is deposited in excess beyond the final required geometry, creating a preliminary form that can later be selectively machined to achieve the precise final surface finish. This preliminary over-deposition enables subsequent refinement.
2Manufacturing precision
If selective machining is performed to achieve smooth surface finishes, then manufacturing precision improves, but productivity decreases
Solution Approach 1:
Machining and surface finishing operations are applied selectively only to specific areas where high surface quality is required, rather than treating the entire deposited layer. This localized approach preserves productivity while achieving necessary precision.
Solution Approach 2:
The deposition process intentionally applies partial action by depositing material beyond what is ultimately needed, creating excess material that is later removed through selective machining. This excessive initial deposition enables subsequent precision work on only the necessary portions.
3Ease of manufacture
If layer-by-layer deposition is used to build complex models, then manufacturing complexity is reduced, but production time increases
Solution Approach 1:
The process maintains continuous useful action by combining deposition and machining operations in an integrated sequence without idle transitions. Material is continuously deposited and then continuously refined, maximizing productive engagement of the system throughout the fabrication process.
Solution Approach 2:
Multiple operations - deposition, selective machining, and surface finishing - are merged into an integrated process flow where each operation seamlessly transitions to the next, reducing total production time while maintaining the ability to create complex geometries.
4Manufacturing precision
If excess material is deposited to ensure complete coverage, then manufacturing precision improves, but material waste increases
Solution Approach 1:
Excess material that is deposited beyond the final geometry is systematically removed through selective machining operations. This discarding of surplus material is necessary to achieve the precise final form, with the understanding that the excess was temporarily required during the construction process.
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 rapid production of three-dimensional models with smooth, high-quality surface finishes by depositing and removing materials efficiently, overcoming the limitations of previous methods in terms of speed and material usage.
Implementation Method 1
both materials in each layer are deposited, the grid is moved to the next layer so that the two materials may fill the space left by the removed grid and thereafter solidify in contact with each other
Implementation Method 2
The second material is subsequently removed by heating, cutting, melting, chemical reacting, and so on, to leave the desired article
Implementation Method 3
The second material is subsequently removed by heating, cutting, melting, chemical reacting, and so on, to leave the desired article
Data Source
AI summary
A method of fabricating a three dimensional model from a composite model formed by a plurality of layers. The composite model comprises at least one shell material encasing and enclosing a build material. The method comprises the steps of (1) depositing a build layer of the build material onto a preceding layer, (2) removing a selected area of the build material from the deposited build layer; (3) depositing the shell material in any removed selected area of the build material; and (4) reducing the build layer to a desired final thickness for supporting a next build layer. Then repeatedly repeating steps (1) through (4) for each build layer until the composite model is completed. Finally, the undesired extraneous material, and possibly the shell, are removed to obtain the final model.