3D Printing Gap Filling for Thickness Strength
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Solution Overview
Problem
Existing three-dimensional shaped article production methods fail to adequately ensure strength in the thickness direction and are prone to voids, despite efforts to fill void regions.
Innovation Solution
A method that specifies and fills gap portions within the three-dimensional shaped article by generating second shaping data to adjust layer thickness and path widths, using a control unit to eject shaping material according to these data, thereby improving structural integrity and reducing void occurrence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If void regions are filled by extruding material according to generated build path and remnant path, then void occurrence is suppressed, but strength in thickness direction is not sufficiently ensured
Solution Approach 1:
The patent segments the shaping process into two distinct phases: first shaping the main body with standard layer thickness, then separately filling gap portions with additional material. This segmentation allows optimized handling of different regions - the main body maintains structural integrity while gap portions receive targeted reinforcement to eliminate voids and improve strength in the thickness direction.
Solution Approach 2:
The patent applies different layer thicknesses to different portions of the three-dimensional shaped article. Standard portions are shaped with a first layer thickness, while gap portions are specifically filled with material at a second layer thickness. This local quality approach ensures that reinforcement is applied precisely where needed (in gap portions) without unnecessarily increasing material usage elsewhere.
2Strength
If layer thickness is increased to fill gap portions, then strength in thickness direction is improved, but manufacturing complexity increases
Solution Approach 1:
The patent performs preliminary identification of gap portions during the data generation phase, before the actual shaping process. The control device calculates and determines which portions will be gap portions based on the three-dimensional data, then pre-plans the shaping path to address these areas. This preliminary action simplifies the manufacturing process by eliminating the need for complex real-time adjustments during shaping.
Solution Approach 2:
The system uses its own shaping data and control algorithms to automatically identify and fill gap portions without requiring external intervention or complex additional equipment. The control device self-adjusts the layer thickness and shaping path based on pre-calculated gap portion locations, making the process self-sufficient and reducing manufacturing complexity.
Data Source
AI summary
A three-dimensional shaped article production method for producing a three-dimensional shaped article by ejecting a shaping material to a stage and stacking layers according to a path including multiple partial paths is provided. The production method includes a first step of specifying a gap portion occurring inside the three-dimensional shaped article based on first shaping data having data for shaping a first portion that is a part of the three-dimensional shaped article by stacking layers having a first thickness and data for shaping a second portion that is adjacent to the first portion in a direction orthogonal to a stacking direction of the layers with a layer having a second thickness corresponding to a thickness of the first portion, a second step of generating second shaping data from the first shaping data by changing the first shaping data so as to fill up the gap portion when the gap portion is specified, and a third step of shaping the three-dimensional shaped article by ejecting the shaping material according to the second shaping data.