3D Printing Layer Thickness Strategy for Density and Speed
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Solution Overview
Problem
Existing three-dimensional object manufacturing methods using fluid constituent materials face issues with gaps at adjoining disposition portions due to round cross-sectional shapes, leading to reduced density and increased manufacturing time, especially when forming layers with varying thicknesses.
Innovation Solution
A manufacturing method involving the formation of unit layers with alternating thicknesses, where a first unit layer with multiple thin layers is laminated with a second unit layer of greater thickness, improving contact irregularities and reducing gaps, while using the same ejector for both layers to simplify the apparatus and reduce manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the thickness per layer of fluid constituent material is increased to form a layer, then the manufacturing time is reduced, but gaps are generated in the adjoining disposition portion of the fluid constituent material, causing the density of the three-dimensional object to decline
Solution Approach 1:
The patent divides each unit layer into multiple sub-layers with different thicknesses. Specifically, it forms a first unit layer with multiple first layers having a first thickness, and a second unit layer with a second layer having a second thickness greater than the first thickness. This segmentation allows the thinner first layers to pack more densely while the thicker second layer provides structural support, resolving the contradiction between manufacturing speed and density.
Solution Approach 2:
The patent applies different thickness characteristics to different parts of the unit layer. The first layers have a smaller thickness for dense packing in certain regions, while the second layer has a larger thickness for structural integrity in other regions. This local differentiation of thickness properties allows simultaneous optimization of density and manufacturing efficiency.
2Manufacturing precision
If the thickness per layer of fluid constituent material is reduced to form a layer, then the density of the three-dimensional object is improved, but the manufacturing time of the three-dimensional object is lengthened
Solution Approach 1:
The patent segments the unit layer into multiple sub-layers with varying thicknesses. By including multiple first layers with smaller thicknesses that can be formed quickly, combined with fewer second layers with larger thicknesses, the overall manufacturing time is reduced while maintaining high density through the multiple thin first layers.
Solution Approach 2:
The patent uses partial action by forming only the necessary number of thin first layers (multiple of them) combined with fewer thick second layers. This partial approach to layer formation achieves both high density and short manufacturing time, avoiding the need to form every possible thin layer individually.
3Manufacturing precision
If multiple nozzles are used to make flow rates of constituent material different to form portions having different thicknesses in one layer, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The patent segments the layer formation process into sequential steps: first forming multiple first layers with a first thickness, then forming a second layer with a second thickness. This temporal segmentation allows a single nozzle to produce different thicknesses by controlling the ejection process sequentially, avoiding the need for multiple nozzles with different flow rates and simplifying the apparatus configuration.
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 effectively suppresses gap generation and shortens manufacturing time by enhancing contactability between layers, improving the density and surface quality of the three-dimensional object without requiring multiple ejectors or complex apparatus configurations.
Implementation Method 1
since a force acts on the fluid constituent material such that a cross sectional shape becomes round by surface tension
Data Source
AI summary
Provided is a manufacturing method of a three-dimensional object for manufacturing a three-dimensional object by laminating unit layers using a fluid constituent material. The manufacturing method includes a unit layer formation step of forming the unit layer of one layer by forming a first unit layer in which first layers each having a first thickness are laminated and then forming a second unit layer formed of a second layer having a second thickness greater than the first thickness to adjoin the first unit layer. By executing such a manufacturing method of the three-dimensional object, it is possible to manufacture a highly dense three-dimensional object in a short time.