3D Shaping Method with CAD-Defined Cutting Allowances
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Solution Overview
Problem
Current three-dimensional shaping methods lack objective standards for setting cutting allowances and the order of cutting steps, leading to inefficient and inaccurate shaping processes.
Innovation Solution
A method involving CAD/CAM system-defined machining units with specific cutting allowances on lateral and upper peripheries, where the thickness of the cutting allowance on the upper sides is greater than on the peripheral sides, and a systematic approach to lamination and cutting to optimize cutting without waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cutting allowance is added by repeating lamination steps in three-dimensional shaping, then the target shape can be achieved, but the process becomes inefficient and lacks standardized procedures
Solution Approach 1:
The patent applies preliminary action by pre-calculating and setting the cutting allowance thickness before the lamination process begins. The CAD/CAM system determines the optimal allowance thickness based on the target shape requirements, and this information is used to guide the subsequent lamination and cutting operations, avoiding trial-and-error approaches
Solution Approach 2:
The patent segments the shaping process into distinct standardized phases: lamination phase (building up material with cutting allowance), cutting phase (removing the allowance), and finishing phase (achieving final dimensions). This segmentation allows each phase to be optimized independently and provides clear procedural guidance for operators
2Manufacturing precision
If cutting allowance is provided in three-dimensional shaping, then finishing to prescribed dimensions is enabled, but determination of allowance thickness and cutting order lacks objective standards
Solution Approach 1:
The patent changes the parameter of cutting allowance thickness from an undefined variable to a specifically determined value. The CAD/CAM system calculates the optimal allowance thickness based on factors such as material properties, target geometry, and cutting tool capabilities, providing an objective standard for what was previously a subjective decision
Solution Approach 2:
The patent implements feedback by using the CAD/CAM system to continuously monitor and adjust the lamination and cutting processes. The system compares the current state with the target shape and modifies subsequent operations accordingly, ensuring that the cutting allowance is appropriately managed throughout the manufacturing process
3Manufacturing precision
If cutting steps are performed after lamination in three-dimensional shaping, then the target shape is achieved, but waste generation increases without optimized cutting sequences
Solution Approach 1:
The patent applies preliminary action by pre-determining the optimal cutting sequence and allowance distribution before manufacturing begins. The CAD/CAM system analyzes the target geometry and calculates the most efficient path for removing material, minimizing waste while ensuring the final shape meets specifications
Solution Approach 2:
The patent applies local quality by varying the cutting allowance thickness and cutting approach according to the specific requirements of different regions of the workpiece. Critical areas receive greater allowance and more careful cutting, while less critical areas use minimal allowance, optimizing the balance between precision and material conservation
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 efficient cutting with reduced waste by strategically setting cutting allowances and ordering cutting steps, ensuring accurate shaping of complex three-dimensional objects.
Implementation Method 1
a sintering step in which the flat surface is irradiated with a laser beam or electron beam
Implementation Method 2
a sintering step in which the flat surface is irradiated with a laser beam or electron beam
Implementation Method 3
a sintering step in which the flat surface is irradiated with a laser beam or electron beam
Data Source
Figure 1(a)~1(e)
Figure 2(a)~2(f)
Figure 3(a)~3(f)
AI summary
[Purpose] To provide a three-dimensional shaping method based on efficient and reasonable steps, where setting of a cutting allowance is assumed. [Solution Means] The object can be achieved by a three-dimensional shaping method wherein the following steps are carried out, after a lamination step, in which the steps of forming a powder layer, flattening with a squeegee and sintering are repeated, is followed by cutting of the surface of the laminate. 1. Setting the overall shape of an object to be shaped 1 by a CAD/CAM system, and setting machining units 11 that form the overall shape and cutting allowances 2 on peripheral sides and upper sides of each of the machining units 11. 2. Cutting of the peripheral sides and upper sides according to a prescribed order, after lamination with addition of a cutting allowance 2 on the peripheral sides of each machining unit 11, and after carrying out lamination to the thickness of the cutting allowance 2 on the upper side of the machining unit 11 and the machining unit 11 adjacent above the machining unit 11. 3. Continuing repetition of step 2, from the lowest machining unit 11 to the topmost machining unit 11.