3D Printing Internal Support for Low-Filling-Rate Objects
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Solution Overview
Problem
Existing methods for manufacturing three-dimensionally shaped objects with low filling rates often result in gaps inside the object, causing it to shift due to gravity before curing, which decreases shaping accuracy.
Innovation Solution
A method involving the generation of specific shaping data to discharge shaping and support materials in a controlled manner, with the support material being discharged into gaps between segments of the shaping material path, forming a support structure within the object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a low-filling-rate shaped object is manufactured, then material consumption is reduced, but gaps are present inside the shaped object causing position shift due to gravity before curing, which decreases shaping accuracy
Solution Approach 1:
The patent divides the inner region into multiple discharge paths with segments, creating intentional gaps between segments. This segmentation allows the object to maintain structural integrity while reducing material consumption, as the gaps prevent continuous material filling that would increase weight and material usage.
Solution Approach 2:
The patent introduces support material as an intermediary substance discharged into the gaps between segments of the shaping material. This support material acts as a temporary mediator that prevents position shift due to gravity, allowing the shaping process to maintain accuracy even with low filling rates. The support material is later removed after curing.
2Manufacturing precision
If support material is discharged into gaps between segments of shaping material path, then position shift due to gravity is suppressed, but device complexity increases due to multiple discharge paths and support structure
Solution Approach 1:
The patent merges the contour region discharge path and inner region discharge paths into a unified shaping process. The support material discharge paths are integrated with the shaping material discharge paths, allowing both materials to be discharged from the same discharger system. This merging reduces device complexity compared to having completely separate systems for shaping and support materials.
Solution Approach 2:
The patent changes the discharge parameters (quantity, path, timing) of materials based on the filling rate designation. The control section adjusts discharge quantities and paths dynamically, allowing the system to adapt to different shaping requirements without requiring physically different discharge mechanisms. This parameter-based control simplifies the device while maintaining precision.
3Manufacturing precision
If multiple discharge paths are used for shaping and support materials, then shaping accuracy is improved, but manufacturing time increases due to multiple data generation and discharge steps
Solution Approach 1:
The control section generates all necessary shaping data (first shaping data for contour region, second shaping data for inner region, and third shaping data for support structure) in advance before the actual shaping process. This preliminary data generation allows the discharger to execute the multi-path discharge operation without real-time decision delays, reducing manufacturing time while maintaining the precision benefits of multiple discharge paths.
Solution Approach 2:
The patent implements continuous discharge operations where the discharger alternates between discharge paths without stopping. The control section coordinates the discharge of shaping material and support material through different paths in a continuous sequence, eliminating idle time between discharge operations. This continuity maintains shaping accuracy while minimizing manufacturing time.
Data Source
AI summary
A method for manufacturing a three-dimensionally shaped object includes a first step of acquiring designation information that designates a filling rate of a shaped object, a second step of generating first shaping data containing information on a first discharge quantity and a first discharge path and instructing formation of the shaped object in a contour region, a third step of generating second shaping data based on the designation information, the second shaping data containing information on a second discharge quantity and a second discharge path and instructing formation of the shaped object in an inner region, a fourth step of generating third shaping data containing information on a third discharge quantity and a third discharge path and instructing formation of a support structure in the inner region, a fifth step of shaping a three-dimensionally shaped object, and a sixth step of separating the support structure from the shaped object, and the fourth step includes generating, in one of the layers, the third shaping data in such a way that the third discharge path is at least partially located in a gap between segments of the second discharge path.