3D Shaping with Deformation-Compensated Layer Cutting

Solution Overview

Problem

Existing three-dimensional shaping methods face challenges in maintaining shaping accuracy due to deformation from thermal stress and require excessive shaping time, especially when cutting is performed after deformation stabilization.

Innovation Solution

A three-dimensional shaping apparatus that predicts and corrects for deformation during the formation process by using cutting data generated based on shape data and deformation simulations or past data, allowing for timely cutting to achieve the target shape without waiting for deformation stabilization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If cutting is performed after waiting for deformation stabilization, then shaping accuracy is improved, but shaping time increases

Engineering Contradiction:

Improveshaping accuracyVSAvoidshaping time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system performs preliminary calculations to predict deformation occurring during formation, and pre-corrects cutting data accordingly. This allows cutting to be performed immediately after formation without waiting for deformation stabilization, as the predicted deformation is already compensated for in the cutting parameters.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system incorporates feedback from deformation prediction models that continuously monitor and calculate expected deformation during the formation process. This feedback is used to dynamically adjust cutting data, enabling real-time compensation for thermal stress-induced deformation without requiring extended waiting periods.

Inventive Principle:

Principle #23Feedback

2Productivity

If cutting is performed immediately after formation, then shaping time is reduced, but deformation from thermal stress compromises accuracy

Engineering Contradiction:

Improveshaping speedVSAvoidshaping accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system performs preliminary calculations to predict deformation occurring during formation, and pre-corrects cutting data accordingly. This allows cutting to be performed immediately after formation without waiting for deformation stabilization, as the predicted deformation is already compensated for in the cutting parameters.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system converts the harmful effect of thermal stress-induced deformation into a beneficial outcome by using deformation prediction models to pre-calculate and compensate for the deformation. The deformation that would normally compromise accuracy becomes a predictable factor that can be corrected in advance, enabling immediate cutting while maintaining precision.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Device complexity

If cutting data is not corrected for deformation, then the process is simpler, but the target shape cannot be achieved due to thermal stress deformation

Engineering Contradiction:

Improveprocess complexityVSAvoidshape accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The system performs preliminary calculations to predict deformation occurring during formation, and pre-corrects cutting data accordingly. This allows cutting to be performed immediately after formation without waiting for deformation stabilization, as the predicted deformation is already compensated for in the cutting parameters.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system changes the parameters of cutting data by incorporating deformation predictions. The cutting data is transformed from raw shape data into corrected cutting instructions that account for expected thermal stress deformation, enabling accurate shaping without complex real-time adjustment mechanisms.

Inventive Principle:

Principle #35Parameter changes

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

Improves shaping accuracy by reducing the time required and avoiding tool load issues, while maintaining the target shape despite thermal stress-induced deformations.

Implementation Method 1

Additive manufacturing that fuses powder by laser, electron beam or the like and solidifies the fused powder

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

Additive manufacturing that fuses powder by laser, electron beam or the like and solidifies the fused powder

Methodology Applied

Scientific EffectElectron beam heating: Electron Beam

Implementation Method 3

fuses powder by laser, electron beam or the like and solidifies the fused powder

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 4

fuses powder by laser, electron beam or the like and solidifies the fused powder

Methodology Applied

Scientific EffectThermal solidification: Freezing

Implementation Method 5

a moving mechanism configured to move the part and the shaped object relative to each other, in order to form a next part

Methodology Applied

Scientific EffectMechanical motion:

Implementation Method 6

a cutting portion configured to cut the previously formed part

Methodology Applied

Scientific EffectMechanical cutting:

Implementation Method 7

the controller predicts a deformation occurring in the part after the cutting by a stress accompanied with the formation

Methodology Applied

Scientific EffectThermal stress:

Data Source

PatentUS20260091430A1Three-dimensional shaping apparatus

Publication Date: 2026.04.02 MATSUURA MACHINERY CO LTD

AI summary

An apparatus performs three-dimensional shaping by irradiating metal powder with laser to fuse the powder and solidifying the fused powder to form a thin layer, which are repeatedly perfumed, and stacking the formed thin layers. The apparatus cuts the formed thin layers every time a predetermined number of layers have been formed based on cutting data, thereby improving the shaping accuracy of a shaped object. The cutting data defines a shape to be cut, which may a shape S3 obtained by reflecting a displacement d1 between a target shape S1 and a shape S2 including a deformation predicted by a simulation, onto the target shape S1, or a shape S5 obtained by reflecting a displacement d2 between the target shape S1 and a shape including a further predicted deformation, onto the shape S3.