3D Shaping Device Gap Coverage via Discharge Control
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Solution Overview
Problem
In three-dimensional shaped object manufacturing, the existing methods face challenges in maintaining shaping accuracy due to sagging of the shaping material from the nozzle, particularly when the end point of the bulk raster path and the start point of the remaining path are positioned far apart, leading to gaps and reduced accuracy.
Innovation Solution
A method that generates intermediate data including path data and discharge control data to adjust the discharge amount and moving speed of the discharge unit, specifically increasing the width of the shaping material in the second partial path to cover gaps between paths, ensuring continuous shaping without the need for the nozzle to move over the gap, thereby preventing sagging and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the end point of the bulk raster path and the start point of the remaining path are positioned away from each other, then the nozzle can complete the bulk raster path, but the shaping material sags from the nozzle and adheres to the three-dimensional shaped object, lowering shaping accuracy
Solution Approach 1:
The patent applies preliminary action by adjusting the discharge amount of shaping material in advance before the nozzle moves from the bulk raster path to the remaining path. The discharge amount is increased to ensure continuous material supply during the transition, preventing gaps and sagging before they occur. This proactive adjustment maintains shaping accuracy while completing the bulk raster path efficiently.
2Manufacturing precision
If the discharge amount is increased to cover gaps between paths, then shaping accuracy is improved, but the discharge control complexity increases
Solution Approach 1:
The patent applies local quality by implementing position-dependent discharge control. Different discharge amounts are applied at different locations along the path: a first discharge amount during the bulk raster path and a second, adjusted discharge amount during the transition to and along the remaining path. This localized adjustment ensures gap coverage at critical transition zones while maintaining simplicity in other areas.
Solution Approach 2:
The patent changes the discharge parameter dynamically based on the nozzle's position and path segment. The discharge amount is adjusted as a controllable parameter to match the specific requirements of each path section, allowing precise control of shaping material deposition without requiring complex mechanical modifications to the discharge system.
Data Source
AI summary
Provided is a three-dimensional shaped object manufacturing method. The manufacturing method includes a first step of generating intermediate data including (i) path data indicating, by a plurality of partial paths, a path through which the discharge unit discharges a shaping material while being moved and (ii) discharge control data including at least one of discharge amount information indicating a discharge amount of the shaping material in each of the partial paths and moving speed information indicating a moving speed of the discharge unit in each of the partial path, a second step of analyzing the intermediate data to specify a gap portion interposed between a first partial path and a second partial path, a third step of generating shaping data from the intermediate data by changing the discharge control data corresponding to the second partial path so as to increase, in the second partial path, a width of the shaping material stacked on a stage or on a layer that is previously formed, and a fourth step of shaping a three-dimensional shaped object by controlling the discharge unit according to the shaping data.