3D Printing Device with Variable Layer Thickness Zones
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Solution Overview
Problem
Current additive manufacturing methods are limited to producing one 3D product at a time, leading to increased manufacturing time and costs, and lack flexibility in controlling the resolution and porosity of multiple products in a batch.
Innovation Solution
A method and device for additive manufacturing that allows for the simultaneous production of multiple 3D products with different material layer thicknesses in a single batch by setting a reference layer thickness and forming material layers with varying thicknesses, enabling control over resolution and porosity through the application of a binding agent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple 3D products are manufactured simultaneously in one batch with different material layer thicknesses, then productivity is improved and manufacturing time is reduced, but device complexity increases due to the need for variable thickness control mechanisms
Solution Approach 1:
The printing volume is divided into multiple zones, each with its own reference layer thickness setting. This allows different regions of the batch to be printed at different resolutions simultaneously, enabling multiple products with varying requirements to be manufactured in one batch without requiring complex per-product adjustment mechanisms.
Solution Approach 2:
Different material layer thicknesses are applied to different zones within the same printing batch. High-resolution products receive thinner layers while low-resolution products receive thicker layers, allowing each product to have optimized local quality characteristics appropriate to its specific requirements.
2Manufacturing precision
If high resolution is achieved by using thin material layers, then manufacturing precision is improved, but productivity deteriorates due to increased number of layers required
Solution Approach 1:
The patent applies different material layer thicknesses to different zones based on the specific resolution requirements of products in each zone. Products requiring high resolution are printed with thinner layers in dedicated zones, while products with lower resolution requirements use thicker layers, thus achieving high precision where needed without sacrificing overall productivity.
Solution Approach 2:
The printing process is segmented into multiple zones with different thickness parameters. This segmentation allows the system to optimize for precision in specific zones without being constrained by precision requirements across the entire printing volume, thereby maintaining high productivity while achieving high resolution where necessary.
3Productivity
If thick material layers are used to increase productivity, then manufacturing speed is improved, but manufacturing precision deteriorates due to reduced resolution
Solution Approach 1:
The printing volume is divided into zones where some zones use thick layers for high-speed production of low-resolution products, while other zones use thin layers for high-resolution products. This segmentation allows the system to maximize productivity through thick layers without compromising the precision of products that require fine detail.
Solution Approach 2:
Different zones are assigned different layer thickness qualities based on product requirements. Zones producing products that prioritize speed and weight use thicker layers, while zones producing products that prioritize detail and surface quality use thinner layers, thus achieving high productivity overall without sacrificing precision where it matters.
4Device complexity
If uniform material layer thickness is used across all products, then device complexity is reduced, but adaptability deteriorates due to inability to control resolution and porosity individually
Solution Approach 1:
The system segments the printing volume into multiple zones, each with independently configurable reference layer thickness. This segmentation provides adaptability and versatility by allowing different resolution and porosity settings for different products in the same batch, without requiring complex individual control mechanisms for each product.
Solution Approach 2:
The zoning mechanism serves multiple functions simultaneously: it controls resolution, adjusts porosity, optimizes manufacturing speed, and accommodates different product geometries all within a single unified system framework. This multi-functionality provides high adaptability without proportionally increasing device complexity.
Data Source
Figure 1a~1b
Figure 2
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AI summary
The present disclosure relates to a method for manufacturing one or more 3D products by additive manufacturing using a layer-by-layer technique and a 3D printing device. The method comprises the steps of; setting a first thickness (Tr) of a reference layer (50) and forming one or more material layer having a second thickness (T2). The second thickness (T2) is set as a multiple of an integer and said first thickness (Tr) of the reference layer (50), and performing a binding action on said material layer.