3D Printing Support Height Equalization for Multi-Material Switching
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Solution Overview
Problem
Current three-dimensional rapid prototyping methods face inefficiencies when manufacturing multiple identical or similar objects from different solidifiable materials, as they require frequent switching of material sources and alignment with the build platform, prolonging the object build time due to varying section heights along the build axis.
Innovation Solution
The method involves adjusting the removable support section heights of partially-completed objects to equalize the interface distances along the build axis, allowing for concurrent manufacturing of multiple objects from multiple solidifiable materials using a single material container switching operation, thereby maintaining alignment with the build platform and reducing the need for frequent material source changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple material sources are used to manufacture objects from different solidifiable materials, then material diversity is improved, but build time increases due to frequent material switching and alignment operations
Solution Approach 1:
The patent applies preliminary action by pre-positioning multiple material containers at predetermined locations around the build platform before the manufacturing process begins. This allows the system to quickly switch between materials by simply moving to different pre-positioned containers rather than performing time-consuming alignment operations during manufacturing. The interface distance calculations are also performed in advance to ensure seamless material transitions.
Solution Approach 2:
The patent implements dynamics by making the material container positions adjustable and reconfigurable. The system can dynamically adapt to different manufacturing scenarios by changing the arrangement of material containers around the build platform. This dynamic positioning capability allows optimization of material switching efficiency for different object configurations and material combinations.
2Productivity
If objects with varying section heights are manufactured concurrently, then productivity is improved, but alignment complexity increases requiring frequent material source switching
Solution Approach 1:
The patent applies segmentation by dividing the manufacturing process into distinct phases based on object height segments. Objects are grouped by their interface distances, and material switching occurs only when transitioning between these predefined height segments. This segmentation approach allows multiple objects with different final heights to be manufactured concurrently without requiring continuous material switching, as materials are switched only at segment boundaries.
Solution Approach 2:
The patent utilizes parameter changes by calculating and adjusting the interface distances of objects based on their support section heights and first object section heights. By modifying these geometric parameters and establishing predetermined relationships between them, the system can maintain proper alignment with material containers while manufacturing objects of varying heights. The interface distance parameter serves as a key control variable that reconciles height variations across multiple objects.
3Adaptability or versatility
If material switching operations are performed frequently, then material versatility is improved, but manufacturing efficiency decreases
Solution Approach 1:
The patent implements universality by designing a single material container positioning system that can serve multiple material sources. The build platform and material containers are arranged such that one positioning mechanism can access and switch between multiple pre-positioned containers. This multi-functional arrangement allows the system to handle various material combinations without requiring separate positioning systems for each material, thereby maintaining material versatility while reducing operational complexity and improving efficiency.
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 enables the concurrent production of multiple three-dimensional objects from different materials with reduced material switching events, optimizing build time and efficiency by maintaining alignment with a single material container throughout the process.
Implementation Method 1
photopolymer hardening using light or laser curing methods
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
Methods and apparatuses for making multiple three-dimensional objects from multiple solidifiable materials are shown and described. In accordance with the method, the objects are designed with variable removable support heights along the build axis so that each object has an interface between first and second materials that is the same height from the build platform. The technique simplifies the process of producing multiple three-dimensional objects from multiple solidifiable materials which may have different build axis heights of first and second finished object sections so that the sources of solidifiable materials need only be switched once during the building of multiple objects.