3D Printed Composite Object Using Toy Blocks and Granular Fillers
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Solution Overview
Problem
Conventional 3D printing techniques result in high material and production costs due to the need for extensive use of expensive special-purpose materials and long printing times, while also potentially compromising the strength and quality of the produced objects, especially when attempting to create complex structures.
Innovation Solution
A composite object is created by combining a first object, typically made of assemblable toy blocks or other materials, with a second object produced through 3D printing, where the second object covers at least a portion of the first object's surface, reducing material usage and printing time, and enhancing the strength and quality of the composite object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the inside of an object is completely filled with 3D printing material to maintain strength, then the strength is maintained, but the material cost increases
Solution Approach 1:
The patent applies porous materials by filling the hollow interior of the 3D printed object with granular filler material (such as sand, gravel, or metal particles) instead of completely filling it with expensive 3D printing resin. This creates a porous composite structure that maintains structural strength while significantly reducing the amount of expensive 3D printing material needed, directly resolving the contradiction between strength and material quantity.
Solution Approach 2:
The patent creates composite materials by combining the 3D printed shell structure with granular filler material inside. This composite construction allows the object to maintain strength through the combination of the printed structural framework and the filler material, while using minimal amounts of expensive 3D printing resin, thus resolving the contradiction between maintaining strength and reducing material consumption.
2Manufacturing precision
If the inside of an object is completely filled with 3D printing material to maintain quality, then the quality is maintained, but the production time increases
Solution Approach 1:
By using porous materials (granular fillers) instead of completely filling the object with 3D printing material, the patent dramatically reduces the printing time required. The filler material can be quickly inserted into the hollow structure without requiring lengthy printing processes, thus maintaining quality while reducing production time loss.
Solution Approach 2:
The patent segments the object construction process into two distinct phases: first printing only the essential structural shell, then separately filling the interior with granular material. This segmentation allows the time-consuming printing process to be minimized to only the critical structural components, while the filler is added separately, thereby reducing total production time while maintaining quality.
3Quantity of substance
If a hollow structure is used to reduce material amount, then material cost decreases, but the strength may not be sufficient
Solution Approach 1:
The patent applies composite materials by combining the 3D printed shell with granular filler material inside the hollow structure. This composite construction compensates for the reduced material amount in the shell by adding filler material that contributes to overall strength, thus maintaining sufficient strength while using less expensive 3D printing material.
Solution Approach 2:
The patent uses porous materials (granular fillers) to fill the hollow structure, creating a composite that maintains strength despite the hollow design. The granular material provides internal support and structural integrity, allowing the object to maintain sufficient strength while using minimal 3D printing material for the shell only.
4Manufacturing precision
If expensive special-purpose material is used for 3D printing to ensure quality, then the quality is maintained, but the material cost increases
Solution Approach 1:
The patent uses porous materials (inexpensive granular fillers) to fill the hollow structure instead of using expensive 3D printing material throughout. This allows the use of costly special-purpose 3D printing material to be limited only to the critical shell structure, significantly reducing material cost while maintaining quality through the composite construction.
Solution Approach 2:
The patent creates composite materials combining expensive 3D printing shell material with inexpensive granular filler. This composite approach allows the expensive material to be used only where structurally critical, while the bulk of the object uses cheap filler material, thus maintaining quality while reducing overall material cost.
Data Source
AI summary
In order to provide a composite object that can be produced at high quality and low cost using a 3D printer, a composite object includes: a first object obtained by assembling one or at least two assemblable toy blocks; and a second object constituted by one or at least two parts produced through 3D printing, and configured to be attached to the first object so as to cover at least a portion except for part of a surface thereof. Accordingly, it is possible to produce an object at high quality and low cost using a 3D printer.