3D Printing Device Bulk Material Volume Tapering
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Solution Overview
Problem
Existing 3D printing methods face challenges in efficiently manufacturing large and geometrically complex products while minimizing material usage and manufacturing time, often resulting in excessive bulk material usage and increased costs due to the need for large build spaces and inefficient recycling of unused material.
Innovation Solution
A method and device for additive manufacturing that evaluates the angle of repose of the material used, applying layers parallel to a support with an angle equal to or lower than the material's angle of repose, forming a tapering bulk material volume with a smaller top portion, reducing the amount of material needed and minimizing wear, and allowing for flexible handling and operation within confined spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If layers are applied at an angle greater than the angle of repose to enable continuous manufacturing, then manufacturing efficiency is improved, but collisions between the print head and accumulated particulate material occur causing damage
Solution Approach 1:
The patent changes the critical parameter from layer application angle to angle of repose ratio. By maintaining the layer application angle within the angle of repose limit, the system prevents particulate material collapse and print head collisions, ensuring reliable operation while achieving continuous manufacturing through optimized layer deposition patterns.
2Volume of moving object
If a large build space is used to accommodate abundant bulk material, then large and geometrically complex products can be manufactured, but manufacturing time and material recycling time increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-calculating and optimizing the bulk material volume configuration before manufacturing begins. By using angle of repose-based calculations to determine the minimum necessary bulk material volume, the system prepares an optimized build configuration that reduces both material quantity and manufacturing time while ensuring product quality.
Solution Approach 2:
The patent applies partial action by using only the necessary amount of bulk material required for the specific product geometry, rather than filling the entire build space. This optimized approach uses precisely the right amount of material needed for support and manufacturing, reducing waste and recycling time.
3Adaptability or versatility
If abundant bulk material is used in confined build spaces, then manufacturing flexibility is maintained, but material waste increases and recycling efficiency decreases
Solution Approach 1:
The patent implements feedback by using angle of repose measurements to dynamically optimize bulk material volume calculations. The system continuously monitors material properties and adjusts the bulk material configuration accordingly, ensuring optimal material usage that maintains manufacturing flexibility while minimizing waste and improving recycling efficiency.
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 reduces material requirements, energy consumption, and manufacturing time, while enhancing recycling efficiency and reducing material waste, making the process more cost-effective and efficient for both small and large-scale 3D printing applications.
Implementation Method 1
The material used in the material layers is evaluated to establish the angle of repose of the material. The at least one layer applying unit applies the material layers parallel to the support, the plurality of material layers being deposited such that at least one side of the bulk material volume has an angle with respect to the support that is equal to, or lower, than the angle of repose for the material used
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
The present disclosure relates to a method for manufacturing of one or more 3D products by additive manufacturing using a layer-by-layer technique using a3D printing device (1). The 3D printing device (1) comprises at least one layer applying unit (3) for depositing a plurality of material layers, a support (4) arranged to receive the material layers, and a layer bonding unit (5) for binding selected portions of the material layers together such that the one or more 3D products are formed. The at least one layer applying unit (3) applying the material layers parallel to the support (4). The method comprising the steps of depositing the material layers forming a bulk material volume (51, 51', 51''). The material layers are applied such that the bulk material volume (51, 51', 51'') comprises a base portion (52) and a top portion (53), whereby the bulk material volume (51, 51', 51'') is formed such that the top portion (53) is smaller than the base portion (52). A 3D printing device is further disclosed.