3D Shaping with Reheating and Secondary Filling for Dimensional Accuracy
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Solution Overview
Problem
Existing three-dimensional shaping methods using fused deposition modeling often result in lacking or excess portions due to material shrinkage, leading to inaccuracies in the final product, as these irregularities may not be fully addressed by cutting processing, compromising the dimensional accuracy of the shaped article.
Innovation Solution
A method and apparatus that include a shaping step with a cutting allowance, followed by measurement and comparison to identify and correct excess or lacking portions through additional cutting and shaping processes, ensuring accurate removal or filling of these irregularities before finalizing the product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cutting processing is performed on the three-dimensional shaped article, then the target shape can be achieved, but lacking portions or excess portions may remain due to shrinkage by cooling or shaping accuracy
Solution Approach 1:
The patent implements a feedback mechanism where the three-dimensional shape measurement unit measures the actual shape of the shaped article, and the controller compares the measured shape with the target shape to identify lacking or excess portions. Based on this feedback, the system automatically generates additional shaping data to correct the identified deviations, ensuring consistent quality and dimensional accuracy.
Solution Approach 2:
The patent applies preliminary action by adding a cutting allowance to the target shape data before shaping. This preliminary modification of the shaping data ensures that the initial shaped article includes extra material that can be removed during cutting processing, compensating for anticipated shrinkage and shaping inaccuracies before the actual shaping occurs.
2Manufacturing precision
If additional shaping steps are performed to fill lacking portions, then dimensional accuracy is improved, but production time increases
Solution Approach 1:
The patent applies partial action by performing additional shaping only on the specific lacking portions identified through measurement and comparison, rather than re-shaping the entire article. The system generates additional shaping data only for the regions where deviations are detected, minimizing unnecessary processing time while maintaining dimensional accuracy.
3Manufacturing precision
If multiple cutting and shaping steps are performed, then dimensional accuracy is improved, but process complexity increases
Solution Approach 1:
The patent merges multiple operations into an integrated automated system. The controller combines shaping, cutting, measurement, and correction processes into a unified workflow where shaping data is automatically generated and updated based on measurement feedback. This integration reduces manual intervention and simplifies the overall process despite multiple steps being involved.
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 production of three-dimensional shaped articles with high dimensional accuracy by systematically addressing and correcting irregularities, preventing residual errors and ensuring a precise final product.
Implementation Method 1
a heating unit configured to heat the upper face of the shaped first portion to a temperature equal to or higher than a melting point of the thermoplastic resin
Implementation Method 2
a shaping unit configured to eject molten material onto the heated upper face of the shaped first portion
Implementation Method 3
ejecting the molten material so as to fill the specified lacking portion
Data Source
AI summary
A method for producing a three-dimensional shaped article includes shaping a first portion constituting at least a part of the three-dimensional shaped article by ejecting a molten material according to shaping data generated based on a shape resulting from adding a cutting allowance for cutting processing to a target shape of the three-dimensional shaped article, performing the cutting processing for the first portion, obtaining a measured shape of the first portion by measuring a shape of the first portion, specifying an excess portion and a lacking portion of the first portion by comparing a shape of a portion corresponding to the first portion of the target shape with the measured shape, performing the cutting processing for the specified excess portion when the excess portion was specified, and ejecting the molten material so as to fill the specified lacking portion when the lacking portion was specified.