3D Printing Perimeter Generation via Binding Substance Segmentation
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Solution Overview
Problem
Current 3D printing methods face challenges in efficiently forming complex three-dimensional objects with precise control over layer thickness and perimeter generation, often resulting in deviations from the intended design and requiring multiple iterations for accurate formation.
Innovation Solution
A method involving a powder bed with a binding substance applied in a controlled manner to create positive and negative areas, followed by heating and separation techniques to form the object, utilizing multi-axis machine tools and energy beams to generate perimeters in accordance with a model design, allowing for precise layer formation and object creation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional 3D printing methods are used to form complex three-dimensional objects, then the objects can be created with varying materials and shapes, but the layer thickness control and perimeter generation accuracy deteriorate, resulting in deviations from the intended design
Solution Approach 1:
The patent divides the 3D printing process into distinct segmentation steps: (a) providing a powder bed with binding substance, (b) generating first boundaries to create positive and negative areas, (c) generating secondary boundaries to form sub-areas, and (d) separating positive and negative objects. This segmentation allows independent control of each operation, improving layer thickness control and perimeter accuracy while reducing design deviations.
2Manufacturing precision
If multiple iterations are performed to achieve accurate formation of three-dimensional objects, then the manufacturing precision improves, but the productivity and time efficiency deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-defining positive and negative areas through boundary generation before the actual object formation. The first boundaries create positive areas and negative areas, and secondary boundaries further divide negative areas into sub-areas. This preliminary structuring ensures that when objects are separated, the desired precision is achieved in a single iteration without requiring multiple reprints.
3Stability of the object's composition
If binding substance is applied to the powder bed surface, then the layers can be formed and bound together, but pooling of binding substance or physical disturbance of powder particles may occur, deteriorating the surface quality and layer uniformity
Solution Approach 1:
The patent applies local quality by providing binding substance on only at least a portion of the exposed surface of the powder bed, rather than uniformly across the entire surface. The binding substance is selectively applied to specific areas where it is needed for layer binding, preventing pooling in unnecessary regions and avoiding physical disturbance of powder particles in areas not requiring binding. This localized approach maintains both structural integrity and surface quality.
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 efficient and precise formation of three-dimensional objects with accurate layer thickness and perimeter generation, reducing the need for multiple iterations and improving the fidelity to the intended design.
Implementation Method 1
providing a powder bed comprising a binding substance on at least a portion of an exposed surface of the powder bed
Implementation Method 2
heating the positive object, wherein the heating is bulk heating of the positive object, which bulk heating comprises sintering individual particles of the powder material in the positive object
Data Source
AI summary
The present disclosure provides systems and methods for the formation of three-dimensional objects. A method for forming 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.