3D Object Manufacturing via Integrated Layer Processing
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Solution Overview
Problem
Current 3D printing technologies face challenges in alignment and precision during the assembly of media layers, leading to inefficiencies and reduced quality in the production of colored 3D objects, particularly due to the complexity of using colored sheets and inks, and the need for improved speed, material efficiency, and color accuracy.
Innovation Solution
A method and system for processing media layers in a common reference plane, integrating cutting, printing, and adhesive application to form 3D objects, where each layer is cut and printed in situ, allowing for precise control over ink application and barrier layers to achieve desired colors and transparency, reducing waste and processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate modules (printing, cutting, bonding) are used to process media layers, then functionality is comprehensive, but device complexity and alignment precision deteriorate
Solution Approach 1:
The patent combines printing, cutting, and bonding operations into a single integrated module that processes media layers in one location. This consolidation reduces the number of separate modules needed, simplifying the overall device structure while maintaining comprehensive functionality. The integrated module processes the entire media layer stack in a single location, eliminating the need for multiple separate processing stations and reducing alignment complexity between modules.
Solution Approach 2:
The integrated processing module performs multiple functions (printing, cutting, bonding) within a single device unit. This multi-functional approach allows one module to replace what would traditionally require several separate modules, reducing device complexity while maintaining the versatility needed for complete media layer processing.
2Ease of manufacture
If media layers are processed in separate locations, then processing can be specialized, but manufacturing precision and time efficiency worsen
Solution Approach 1:
By merging printing, cutting, and bonding operations into a single integrated processing location, the patent eliminates the need to transport media layers between separate processing stations. This ensures that all processing steps occur in the same reference plane, maintaining precise alignment throughout the manufacturing process while still allowing each operation to be performed with specialized equipment within the integrated module.
3Adaptability or versatility
If colored sheets and inks are used, then color capability is improved, but device complexity and process difficulty worsen
Solution Approach 1:
The patent applies printing to the entire media layer stack before cutting and bonding operations. By completing the coloring process beforehand, the system avoids the complexity of handling and aligning pre-colored materials through multiple separate processing stations. The integrated module then processes the pre-printed layers together, maintaining color consistency while simplifying the overall process.
4Manufacturing precision
If multiple processing steps are performed sequentially, then processing is thorough, but productivity and time efficiency worsen
Solution Approach 1:
The integrated processing module performs printing, cutting, and bonding operations in continuous sequence without interrupting the media layer stack. This continuous processing approach maintains thoroughness by completing all necessary steps while significantly improving productivity by eliminating the time required to transport and reposition materials between separate processing stations.
Data Source
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AI summary
There is provided a method of manufacturing a 3D object from a plurality of media layers including processing a media layer to define a layer of the 3D object, said processing including: cutting the media layer to define the profile of the layer; printing the media layer to define the colour of the layer. The processing including the cutting and printing of the media layer is done in a common reference plane and a plurality of media layers are processed and assembled at the build location to form the object.