3D Printed Unifying Shell for Discrete Element Positioning

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Solution Overview

Problem

Existing 3D inkjet printing methods struggle to maintain the spatial relative positioning of printed objects and assemblies after support structures are removed, leading to disassembly and loss of original positioning.

Innovation Solution

A method and system for 3D printing that involves defining a unifying shell enveloping discrete elements with transparent building material and assigning building materials to form a 3D object with discrete elements connected by a unifying element, using techniques like bounding boxes and polyhedrons to ensure connectivity and maintain spatial positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If support structures are used to sustain specific regions during printing, then printing stability is improved, but spatial relative positioning is lost after support removal

Engineering Contradiction:

Improveprinting stabilityVSAvoidspatial relative positioning

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The support structure is segmented into multiple discrete support elements rather than a continuous mass. Each support element is individually positioned and sized to provide minimal necessary support, allowing for precise control over the discrete elements being supported and reducing interference with final positioning.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A unifying element is introduced as an intermediary component that connects the discrete elements to each other and to the build plate. This unifying element provides the necessary structural support during printing while maintaining the spatial relationships between discrete elements, eliminating the need for traditional support structures that would interfere with final positioning.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If discrete elements are printed separately, then manufacturing flexibility is improved, but spatial relative positioning is lost

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidspatial relative positioning

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

Multiple discrete elements are merged into a single unified printed structure by embedding them within a common unifying element. This allows each discrete element to be manufactured with flexibility and customization while the unifying element ensures they maintain their intended spatial relative positioning as a coordinated assembly.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The spatial relationships and positions of discrete elements are predetermined and encoded in the digital model before printing begins. The unifying element is designed in advance to connect these elements at their specific predetermined positions, ensuring that when printed, the elements automatically achieve their correct spatial configuration without requiring post-printing assembly or adjustment.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If a unifying element is added to maintain positioning, then spatial relative positioning is preserved, but device complexity increases

Engineering Contradiction:

Improvespatial relative positioningVSAvoidstructure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The unifying element is implemented as a thin-walled shell or membrane structure rather than a bulky solid form. This thin-film approach provides sufficient structural support to maintain spatial relationships between discrete elements while occupying minimal space and adding minimal complexity to the overall printed object.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The unifying element serves multiple functions simultaneously: it acts as a structural support during printing, provides mechanical connection between discrete elements, maintains spatial relative positioning, and can serve as part of the final product's aesthetic or functional design. This multi-functionality reduces the need for separate dedicated support structures.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

The method ensures that printed discrete elements remain connected and maintain their original spatial relative positioning, allowing for precise assembly and presentation of objects in their intended configuration.

Implementation Method 1

building materials are selectively jetted from one or more print heads and dispensed onto a fabrication tray to form the 3D object, layer-by-layer

Methodology Applied

Scientific Effect3D Printing: 3D Printing

Data Source

PatentEP4729212A2Method of printing a three-dimensional object comprising a plurality of discrete elements

Publication Date: 2026.04.22 STRATASYS LTD

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AI summary

A method of printing a 3D object comprising a plurality of discrete elements, the method comprising receiving a 3D digital model of the object and dispensing, in layers, one or more building materials to form the 3D object.