3D Printing Sub-Object Segmentation for Distortion Control
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Solution Overview
Problem
Large-format three-dimensional object production via radiation-solidifiable powder-like building materials faces challenges such as material and process-related distortion effects, and handling difficulties due to the size of the objects.
Innovation Solution
A method involving the formation of a support structure within the same process as the three-dimensional object, using laser sintering or melting, where the object is segmented into sub-objects supported by the structure, with connection areas formed to stabilize and connect these sub-objects, allowing for reduced distortion and improved manageability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If large-format three-dimensional objects are produced by successively solidifying layers of radiation-solidifiable powder-like construction material, then the production of complex technical components is enabled, but material and process-related distortion effects occur that make it difficult to achieve exact final dimensions
Solution Approach 1:
The three-dimensional object is divided into multiple sub-objects that are produced separately and then connected. This segmentation reduces the size of individual solidification zones, thereby minimizing material and process-related distortion effects in each sub-object while still enabling production of large-format complex components through subsequent connection of the sub-objects
Solution Approach 2:
The support structure is adapted in its geometric shape, particularly in its cross-section, to the geometric shape of the three-dimensional object. This local adaptation allows the support structure to provide optimized support at different locations, reducing distortion effects in specific critical areas while maintaining overall dimensional accuracy
2Volume of moving object
If large-format three-dimensional objects are produced, then complex technical components can be manufactured, but handling during or after production presents challenges
Solution Approach 1:
By dividing the large-format object into smaller sub-objects, the handling difficulty is significantly reduced. Each sub-object is smaller and easier to manipulate during and after production, while the support structure enables these sub-objects to be handled as a coordinated assembly rather than a single cumbersome large object
Solution Approach 2:
The support structure serves as an intermediary that facilitates handling of the sub-objects. During production, the support structure holds the sub-objects in their correct positions, and after production it enables easy removal and separate handling of individual sub-objects, thereby improving overall handling ease
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 method effectively reduces material and process-related distortions and enhances the manageability of large-format three-dimensional objects by segmenting them into smaller sub-objects supported by an adaptive support structure, ensuring precise positioning and stable connection, facilitating the production of complex technical components like turbine blades and wing elements.
Implementation Method 1
The layers are irradiated with an irradiation device and thereby solidified at the steles corresponding to the respective cross-section of the object. For this purpose, the irradiation device usually comprises a scanner for deflecting electromagnetic radiation from a radiation source, which is usually designed as a laser.
Implementation Method 2
a laser sintering or laser melting system with the usual components is provided
Implementation Method 3
laser sintering processes (SLS processes for short) and laser melting processes (SLM processes for short)
Data Source
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AI summary
The invention relates to a method for producing a three-dimensional object 1 by successively solidifying layers of a radiation-hardenable powder-like building material, comprising the following process steps: providing a laser sintering or laser melting system with a housing, a build chamber arranged therein, a coating device for applying building material layer by layer, an irradiation device for irradiating the applied layers of the building material, and a group structure onto which the object and/or a support structure for the object is additively built; forming the support structure 2 for at least partially supporting the three-dimensional object 1 to be produced by successively solidifying layers of the building material; forming several,each forming a specific sub-object 1 of the three-dimensional object to be produced by successively solidifying layers of the building material, wherein at least one sub-object 6 is formed at least section by section on the support structure 2, forming connection areas 7 between the sub-objects 6 for at least section by section connecting the sub-objects 6 to form the three-dimensional object, removing the three-dimensional object 1 from the support structure 2.