3D Object Outer Layer and Inner Structural Member Design
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Solution Overview
Problem
Forming large-sized three-dimensional objects with existing three-dimensional forming apparatuses is challenging due to increased material usage, weight, and potential strength issues, particularly when attempting to minimize weight by making the objects hollow, which can compromise structural integrity.
Innovation Solution
A three-dimensional object configuration comprising an outer-layer member made of divided pieces formed from functional ink and an inner structural member, where the inner structural member is lighter and made of a different material, such as thermoplastic resin, to support the outer-layer member, reducing overall weight and cost while maintaining strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the three-dimensional object is made hollow to decrease weight, then the weight is reduced, but the strength may be insufficient
Solution Approach 1:
The three-dimensional object is divided into multiple sections along the deposition direction, with each section formed as a separate hollow structure. This segmentation allows the object to maintain light weight while the distributed structure provides adequate strength through multiple load-bearing sections rather than a single hollow cavity
Solution Approach 2:
The patent uses composite construction by combining hollow structural sections with supporting elements. The hollow sections provide weight reduction while internal supports or reinforcing structures maintain the necessary strength, creating a composite system that balances both requirements
2Strength
If the three-dimensional object is formed wholly of ultraviolet curable ink to ensure strength, then the strength is adequate, but the weight increases disadvantageously
Solution Approach 1:
The object is segmented into hollow sections that are formed using ultraviolet curable ink, maintaining strength where needed while removing material from non-critical areas to reduce overall weight
Solution Approach 2:
Different regions of the three-dimensional object have different structural qualities - critical load-bearing areas maintain solid construction with ultraviolet curable ink, while non-critical areas are hollowed out to reduce weight, creating local variations in material distribution
3Strength
If a significant amount of ultraviolet curable ink is used to form large-sized three-dimensional object to ensure strength, then the strength is adequate, but the forming cost and work time increase significantly
Solution Approach 1:
The large-sized object is divided into multiple smaller sections that can be formed independently and more efficiently. This segmentation reduces the total amount of ultraviolet curable ink required for each deposition operation and allows parallel or sequential formation of sections, improving overall productivity
Solution Approach 2:
Instead of forming the entire large object in one continuous deposition process using excessive ink, the patent applies partial action by forming separate sections with appropriate ink amounts, avoiding waste and reducing total forming time through optimized material usage
4Weight of moving object
If the three-dimensional object is made hollow to reduce weight, then the weight is reduced, but the handling becomes more difficult due to potential strength insufficiency
Solution Approach 1:
The hollow object is segmented into multiple sections that can be individually handled and assembled. This segmentation improves handleability by breaking down a large, potentially fragile hollow structure into smaller, more manageable components that are easier to transport and manipulate
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 configuration allows for the creation of large-sized three-dimensional objects that are both strong and lightweight, reducing formation costs and improving handling and production efficiency by using distinct materials for the outer-layer and inner structural components.
Implementation Method 1
ultraviolet curable ink, which is cured when irradiated with ultraviolet light
Implementation Method 2
The inner structural member is disposed in the inner space of the outer-layer member and configured to support the outer-layer member
Data Source
AI summary
A three-dimensional object includes an outer-layer member and an inner structural member. The outer-layer member is a layer to constitute the surface of the three-dimensional object, and includes an inner space. The outer-layer member is made up of a plurality of divided outer-layer pieces formed of build material, which is functional ink ejected from a droplet ejection head and cured. The inner structural member is disposed in the inner space of the outer-layer member and configured to support the outer-layer member.