3D Powder Shaping With Undercut Joining and Interior Space Cutting
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Solution Overview
Problem
Current CAD/CAM systems face challenges in efficiently shaping three-dimensional products by automatically creating cutting paths for interior spaces, particularly when the cutting tool cannot be inserted from the start, leading to unnecessary and inefficient cutting at the top edge of enclosed regions.
Innovation Solution
A method where the top undercut region and bottom interior space-forming region are separately produced and joined, with the CAD/CAM system programmed to automatically avoid cutting in the horizontal direction at the top edge of the interior space by setting commands for further lamination and sintering, allowing for efficient shaping without the need for a planned cutting plane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If the CAD/CAM system automatically creates cutting paths for interior spaces, then the automation of three-dimensional shaping is improved, but unnecessary cutting at the top edge of enclosed regions occurs
Solution Approach 1:
The invention applies preliminary action by defining the opening at the top edge of the interior space before the cutting process begins. The CAD/CAM system is provided with advance information about the opening location, allowing it to pre-calculate and adjust the cutting path to avoid unnecessary cutting at the opening. This preliminary definition enables the automated system to recognize when cutting should be terminated before reaching the top edge, thereby maintaining automation while eliminating wasteful cutting operations.
2Ease of manufacture
If the cutting tool is inserted from the start to create cutting paths, then the cutting path creation is simplified, but it becomes impossible to form enclosed interior spaces like water conduits
Solution Approach 1:
The invention applies segmentation by dividing the three-dimensional shaping process into distinct stages: first forming the interior space structure, then creating cutting paths in subsequent stages. This allows the cutting tool to access the interior space from the top opening after the structure is formed, rather than requiring insertion from the start. The segmentation of the manufacturing process enables both enclosed interior spaces and simplified cutting path creation to coexist.
3Manufacturing precision
If horizontal cutting paths are created in both upper and lower regions of the interior space, then complete interior wall section cutting is achieved, but special programming is required to join the cutting paths
Solution Approach 1:
The invention applies feedback by implementing a cutting path generation method that automatically detects and responds to the opening location. The system continuously monitors the cutting progress and uses the opening position information to dynamically adjust and terminate cutting paths at the appropriate location. This feedback mechanism eliminates the need for complex pre-programming to join cutting paths, as the system automatically manages the cutting path continuity and termination based on real-time position information.
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 eliminates the need for special programming and avoids unnecessary cutting at the top edge, enhancing the efficiency of three-dimensional shaping by allowing the CAD/CAM system to judge the completion of cutting stages accurately, thus preventing horizontal cutting at the opening.
Implementation Method 1
sintering with irradiation of a laser beam or an electron beam
Implementation Method 2
sintering with irradiation of a laser beam or an electron beam
Data Source
Figure 1(a)
Figure 1(b)
Figure 2(a)
AI summary
[Object] To provide a method for efficient shaping of a three-dimensional shaped product that has an undercut region formed on the upper side and forms an interior space on the lower side. [Solution Means] The method for producing a three-dimensional shaped product having an undercut region 1 on the upper side and an interior space 2-forming region on the lower side, by lamination of powder, sintering of laminated layer and cutting of sintered layer, is a method wherein, when a cutting path where the side is a location 23 of the top edge of the interior space 2 has been created during creation of horizontal cutting paths 3 for cutting of the interior space 2-forming region, the CAD/CAM system sets a command for carrying out further lamination at the location 23 of the top edge, or creates a horizontal cutting path 3 on a location that upper side of above the horizontal cutting path 3 by cutting width and sets a command to cutting tool 4 for terminating cutting along the cutting path, thereby it is avoided to cut created horizontal cutting path.