3D Printing Binder Segmentation for Multi-Object Precision

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Solution Overview

Problem

Current 3D printing technologies face challenges in efficiently and accurately printing multiple three-dimensional objects simultaneously, particularly in terms of speed and precision, especially when dealing with diverse shapes and sizes.

Innovation Solution

A method and system for simultaneous 3D printing involving a powder bed with a binder application unit and perimeter generators that apply binding substances and generate perimeters according to a model design, allowing for the simultaneous creation of multiple objects by layering powder material and applying binding substances in accordance with a computer-generated model.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple three-dimensional objects are printed simultaneously using a single binder application unit, then productivity increases, but manufacturing precision deteriorates due to the inability to apply different binding substances with varying viscosities

Engineering Contradiction:

Improveproduction speedVSAvoidprinting accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The binder application unit is divided into multiple independent application units, each capable of applying a different binding substance with specific viscosity characteristics. This segmentation allows simultaneous printing of multiple objects with different material requirements while maintaining precision for each object.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system integrates multiple binder application units into a single printing apparatus, enabling the machine to handle diverse binding substances (e.g., organic and inorganic binders) with different viscosities. This multi-functionality allows the system to maintain high manufacturing precision across various object types while achieving high productivity through simultaneous printing.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Device complexity

If a single binder application unit uses one binding substance for all objects, then device complexity is reduced, but manufacturing precision deteriorates when objects require different binding substances with different viscosities

Engineering Contradiction:

Improvesystem simplicityVSAvoidprinting accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The binder application unit is segmented into multiple independent application units, each dedicated to applying a specific binding substance. This segmentation enables the system to handle objects requiring different viscosities and binder types while maintaining overall system manageability and precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system allows for parameter changes in binding substances (viscosity, organic/inorganic composition) by providing multiple application units that can be selected based on the specific requirements of each object being printed, thereby maintaining manufacturing precision without excessive complexity.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If layers are deposited sequentially for each object, then manufacturing precision is maintained, but productivity decreases due to sequential processing time

Engineering Contradiction:

Improvelayer accuracyVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system merges multiple printing operations into a single simultaneous process by coordinating multiple binder application units and perimeter generators to print multiple objects at the same time. This combining of operations maintains layer accuracy for each object while dramatically reducing total production time.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system enables continuous useful action by having multiple binder application units and perimeter generators operate simultaneously without idle time. Each object receives the necessary binding substances and perimeter generation in parallel, maintaining precision while eliminating the sequential waiting time that would otherwise occur.

Inventive Principle:

Principle #20Continuity of useful action

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

Enables the rapid and precise creation of multiple three-dimensional objects with varying shapes and sizes, significantly reducing production time, with the ability to generate objects in under 24 hours or even 4 hours, while maintaining accuracy and complexity as per the model design.

Implementation Method 1

applying a first binding substance to a first area of a first layer of powder material of the powder bed

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

depositing a second layer of powder material adjacent to the first layer

Methodology Applied

Scientific EffectMaterial deposition and layering: Deposition (physical)

Data Source

PatentUS20210016501A1Devices, systems and methods for printing three-dimensional objects

Publication Date: 2021.01.21 3DEO INC

AI summary

The present disclosure provides systems and methods for printing three-dimensional objects. A method for printing a three-dimensional object may comprise alternately and sequentially applying a stream comprising a binding substance to an area of a layer of powder material in a powder bed, and generating at least one perimeter of the three-dimensional object in the area. The stream may be applied in accordance with a model design of the three-dimensional object. The at least one perimeter may generated in accordance with the model design.