3D Shaping Apparatus with Hardening Acceleration Unit
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Solution Overview
Problem
Existing three-dimensional shaping techniques are costly and inefficient, particularly for producing complex shapes, due to high material costs and lengthy processing times, which also pose challenges in achieving the required mechanical strength and quality.
Innovation Solution
A three-dimensional shaping apparatus and method that utilize additive manufacturing to laminate thermoplastic shaping material and mold material, with a hardening acceleration unit to expedite the hardening process, allowing for the creation of complex shapes using relatively inexpensive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional three-dimensional shaping techniques are used, then mechanical strength and quality can be achieved, but material costs are high and processing time is lengthy
Solution Approach 1:
The shaping process is segmented into distinct lamination steps: depositing thermoplastic shaping material, applying mold material in slurry form, and accelerating hardening. This segmentation allows each step to be optimized independently, reducing overall processing time while maintaining mechanical strength through controlled material deposition and curing sequences
Solution Approach 2:
The mold material is applied in slurry form before final hardening, allowing the material to be positioned and shaped in advance. The hardening acceleration unit then completes the process rapidly, enabling preliminary shaping without waiting for full curing, thus reducing processing time while ensuring final strength requirements are met
2Strength
If conventional three-dimensional shaping techniques are used, then mechanical strength can be achieved, but material costs are high
Solution Approach 1:
The invention changes the physical state and composition parameters of the mold material by using it in slurry form during deposition, then transforming it to a hardened state. This parameter change allows the use of more cost-effective materials that can be easily manipulated in liquid form but provide sufficient strength when hardened, reducing material costs while maintaining mechanical strength
Solution Approach 2:
The process uses composite material deposition by alternating layers of thermoplastic shaping material and mold material. This composite approach allows each material to contribute its optimal properties: the thermoplastic provides structural form and the mold material provides surface quality and strength, achieving required mechanical strength with cost-effective material selection
3Ease of manufacture
If additive manufacturing with lamination is used, then complex shapes can be produced cost-effectively, but hardening time of mold material is lengthy
Solution Approach 1:
The natural chemical hardening process of the mold material is replaced by introducing a hardening acceleration unit that actively accelerates the curing reaction. This substitution transforms a passive, time-dependent chemical process into an actively controlled process, dramatically increasing hardening speed while maintaining cost-effectiveness through simple apparatus additions
Solution Approach 2:
The mold material undergoes an accelerated phase transition from slurry (liquid) to hardened state through the hardening acceleration unit. By controlling and accelerating this phase transition, the process achieves rapid hardening that doesn't compromise the cost-effectiveness of using slurry-form materials, resolving the contradiction between productivity and ease of manufacture
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 cost-effective production of complex three-dimensional shapes with improved mechanical strength and reduced processing time, while also promoting sustainability by using reusable materials.
Implementation Method 1
a head configured to heat and eject a thermoplastic shaping material to laminate the thermoplastic shaping material on the table
Implementation Method 2
a hardening acceleration unit configured to accelerate hardening of the mold material laminated on the table
Implementation Method 3
a squeegee configured to apply a mold material in a slurry form to laminate the mold material on the table
Implementation Method 4
a step of melting the thermoplastic shaping material inside the shaped object and discharging the thermoplastic shaping material that has been melted
Data Source
AI summary
A three dimensional shaping apparatus for performing additive manufacturing includes: a table; a head that heats and ejects a thermoplastic shaping material to laminate the thermoplastic shaping material on the table; a squeegee that applies a mold material in a slurry form to laminate the mold material on the table; and a hardening acceleration unit that accelerates hardening of the mold material laminated on the table.