3D Printing Discharge Control for Gap-Free Layer Formation
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Solution Overview
Problem
Existing three-dimensional shaping methods face challenges in preventing gaps between adjacent partial shaped objects during the manufacturing process, as the discharge amount of shaping material needs to be adjusted based on the adjacency of objects to maintain continuous layers without gaps.
Innovation Solution
A method and apparatus that adjust the discharge amount of shaping material by controlling the plasticizing unit, discharging unit, and moving mechanism, where the discharge amount is set to a first or second discharged shaping amount depending on whether the second partial shaped object is adjacent to the first partial shaped object, ensuring continuous layer formation without gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed discharge amount is used for all partial shaped objects, then the manufacturing process is simple, but gaps occur between adjacent partial shaped objects
Solution Approach 1:
The discharge amount is dynamically adjusted based on the adjacency relationship between partial shaped objects. The control unit changes the discharge amount between a first discharged shaping amount (for non-adjacent objects) and a second discharged shaping amount (for adjacent objects), making the system adaptive rather than fixed
Solution Approach 2:
Different discharge amounts are applied to different regions of the manufacturing process. Specifically, the second discharged shaping amount is used locally at positions where partial shaped objects are adjacent to each other, while the first discharged shaping amount is used in other regions, ensuring precise gap prevention only where needed
2Manufacturing precision
If the discharged shaping amount is increased for adjacent objects, then gaps are prevented, but material usage increases
Solution Approach 1:
The increased material discharge (second discharged shaping amount) is applied only locally at positions where partial shaped objects are adjacent, rather than uniformly across all objects. This ensures continuous layer formation at critical junctions while minimizing unnecessary material consumption in non-adjacent regions
Solution Approach 2:
The patent applies excessive material discharge (second discharged shaping amount) only partially, specifically at adjacent object positions where gap prevention is critical. This partial application of excessive action prevents gaps where needed while avoiding waste in regions where standard discharge amount suffices
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
The method effectively prevents the generation of gaps between partial shaped objects by dynamically adjusting the discharge amount based on adjacency, ensuring a continuous and gap-free three-dimensional shaped object.
Implementation Method 1
a plasticizing step of plasticizing at least a part of a material to generate the shaping material
Implementation Method 2
a layer forming step of shaping, based on shaping data, a plurality of partial shaped objects along a partial route to form a layer on the shaping surface, by discharging the shaping material toward the shaping surface while moving the discharging unit along the partial route
Data Source
AI summary
In a method for manufacturing a three-dimensional shaped object, when an amount of a shaping material discharged toward a shaping surface per unit movement amount of a discharging unit is defined as a discharged shaping amount, in a layer forming step of forming a layer on the shaping surface, in a case in which a second partial shaped object to be shaped is not adjacent to a first partial shaped object that is shaped previously and is shaped with a gap between the first partial shaped object and the second partial shaped object, the second partial shaped object is shaped by setting the discharged shaping amount to a first discharged shaping amount, and in a case in which the second partial shaped object is adjacent to the first partial shaped object, the second partial shaped object is shaped by setting the discharged shaping amount to a second discharged shaping amount that is greater than the first discharged shaping amount.