3D Printed Cover Body Vacuum Formed on Base
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Solution Overview
Problem
Conventional 3D printing methods become inefficient and hazardous when forming objects with high elevation, requiring large ink volumes and posing safety risks due to the need for distant UV curing lamps.
Innovation Solution
The method involves splitting the model into a high elevation/low resolution base part and a low elevation/high resolution cover part, using 3D printing for the cover part and combining it with the base part via vacuum forming, allowing for efficient and safe rendering of fine details.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If 3D printing techniques are used to form high elevation objects, then fine surface details can be rendered with high spatial resolution, but large amounts of ink have to be applied and cured which becomes inefficient
Solution Approach 1:
The model is divided into a base part and a cover part. The base part contains the high elevation bulk structure formed by conventional forming techniques, while the cover part contains the fine surface details formed by 3D printing. This segmentation allows each technique to be applied where it is most effective, avoiding the inefficiency of printing the entire high elevation object.
Solution Approach 2:
Different regions of the object are treated differently: the base part is formed using efficient conventional techniques suitable for bulk material, while the cover part is printed using 3D printing techniques suitable for fine surface details. This local quality approach optimizes the process for each specific region's requirements.
2Reliability
If UV curing lamps are arranged at a large distance above the print surface to cure ink for high elevation objects, then curing can be achieved, but there is a considerable risk of hazard
Solution Approach 1:
By dividing the object into base and cover parts, the cover part requiring UV curing has much lower elevation. This allows UV curing lamps to be positioned close to the print surface, ensuring effective curing while eliminating safety hazards associated with high-distance positioning.
3Productivity
If conventional forming techniques are used for high elevation objects, then large volume bulk bodies can be formed efficiently, but fine surface details cannot be rendered
Solution Approach 1:
The object is segmented into base part (high elevation, low surface detail requirement) and cover part (low elevation, high surface detail requirement). Conventional forming techniques efficiently create the bulk base structure, while 3D printing techniques add the fine surface details on the cover part.
Solution Approach 2:
The patent combines two different manufacturing techniques: conventional forming for the base part and 3D printing for the cover part. The cover part is then matched to the base part using vacuum forming, creating a unified object that benefits from both techniques' strengths.
4Manufacturing precision
If 3D printing is used for the entire object including high elevation, then fine details can be printed, but large amounts of ink have to be applied and cured which becomes inefficient
Solution Approach 1:
The model is divided into base part and cover part. Only the thin cover part containing surface details is printed with ink, while the bulk base part is formed by conventional techniques. This dramatically reduces the volume of ink required compared to printing the entire object.
Solution Approach 2:
Ink is applied only where needed - on the cover part that requires fine surface details - rather than on the entire object. This localized application of ink reduces material consumption while maintaining the desired surface quality.
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 the efficient and safe production of three-dimensional objects with high elevation by utilizing 3D printing for detailed cover parts and conventional techniques for base parts, reducing ink usage and safety hazards while maintaining high spatial resolution.
Implementation Method 1
matching cover body to the base body by vacuum forming
Implementation Method 2
the cured ink has also elastic properties, so that the sheet-like cover body may be stretched locally in order to match the non-euclidian geometry of the base body surface
Data Source
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AI summary
A method of forming a three-dimensional object (38) with a shape determined by model data defining a model (10) of the object, characterized by the steps of: a) splitting the model (10) into a high elevation / low resolution base part (18) and a low elevation / high resolution cover part (20'); b) forming a base body (30) with a shape as determined by the base part (18) of the model; c) employing a 3D printing technique for printing a sheet-like cover body (34) with a shape as determined by the cover part (20') of the model; and d) matching the cover body (34) to the base body (30) by vacuum forming.