3D Shaping via Section Segmentation and Multi-Axis Cutting
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Solution Overview
Problem
Existing methods for forming three-dimensional shaped objects by lamination and cutting are limited by the inability of cutting tools to reach all areas, particularly in complex shapes like tubular structures, leading to incomplete shaping due to the tool's cuttable length constraints.
Innovation Solution
A method involving a three-dimensional shaping device that divides the shaping process into sections, each with a length shorter than the cutting tool's maximum length, allowing for incremental shaping and cutting along multiple directions to accommodate complex geometries without leaving uncut margins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single cutting tool is used to cut the entire three-dimensional shaped object, then the cutting process is simple, but the cutting tool cannot reach all areas particularly in complex shapes like tubular structures
Solution Approach 1:
The three-dimensional shaped object is divided into multiple sections, each with a length shorter than the cutting tool's maximum cuttable length. This segmentation allows the cutting tool to access and cut each section completely, solving the problem of inaccessible areas in complex shapes while maintaining operational simplicity through systematic processing
2Stability of the object's composition
If the three-dimensional shaped object is formed as a single continuous piece, then the structure is complete, but the cutting tool cannot reach all areas for complete cutting
Solution Approach 1:
The object is segmented into multiple sections that are formed and cut separately, then joined together. This approach maintains structural completeness through proper joining of sections while ensuring cutting accessibility by making each section short enough for the tool to reach all areas
Solution Approach 2:
The object is divided not only by length but also by orientation in different directions. Sections are arranged in multiple dimensions and joined accordingly, allowing the cutting tool to access all surfaces of each individual section while reconstructing the complete three-dimensional structure through spatial arrangement
3Shape
If sections are joined to form a longer object, then the desired three-dimensional shape is achieved, but the joining process adds complexity
Solution Approach 1:
The object is segmented into manageable sections that can be independently formed and cut, then joined to create the final three-dimensional shape. This segmentation approach achieves complex geometries while controlling process complexity through systematic formation and joining of standardized sections
4Manufacturing precision
If the cutting tool length is increased to reach all areas, then complete cutting is possible, but the device complexity and cost increase
Solution Approach 1:
Instead of using an excessively long cutting tool, the object is segmented into sections with lengths suitable for standard cutting tools. This approach achieves complete cutting of all areas while avoiding the complexity and cost associated with specialized long-reach cutting tools
Data Source
AI summary
Provided is a method for shaping a three-dimensional shaped object using a cutting tool configured to perform cutting at a first length at maximum in a predetermined cutting direction, the method including: a first section shaping step of shaping a first section having a length in a first direction shorter than the first length by laminating a shaping material; a first section cutting step of cutting the first section with the cutting tool having a cutting direction along the first direction; a second section shaping step of shaping a second section having a length in a second direction shorter than the first length by laminating the shaping material, to connect to a first end surface of the first section in the first direction; and a second section cutting step of cutting the second section along the second direction with the cutting tool having a cutting direction along the second direction.