Additive Manufacturing of 3D Objects via Thermoforming
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Solution Overview
Problem
Current methods for producing three-dimensional objects with large surface areas and small thickness, such as rigid corsets, are inefficient and lack simplicity, as they require complex processes like injection molding, deep drawing, and thermoforming, which are time-consuming and prone to mechanical failure at thin edges.
Innovation Solution
A method involving additive manufacturing where curable polymers or reactive resins with an elastic modulus of ≥ 500 MPa are applied in layers, hardened, and then thermoformed or deep-drawn to create three-dimensional objects, utilizing techniques like fused filament fabrication, ink-jet printing, or photopolymer jetting, allowing for the creation of complex shapes with enhanced structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional rapid prototyping methods are used to produce flat plastic components, then three-dimensional objects can be manufactured, but the process is time-consuming and complex
Solution Approach 1:
The invention merges the additive manufacturing process with traditional forming processes by integrating the layer-by-layer construction of flat components directly onto a support structure, eliminating the need for separate manufacturing steps. This combination reduces both production time and process complexity while maintaining the ability to create complex three-dimensional objects.
Solution Approach 2:
The invention performs preliminary action by first creating the flat plastic component with the desired surface structure using additive manufacturing, and then subsequently forming it into the final three-dimensional shape. This preliminary construction of the base layer simplifies the overall process by separating the surface creation from the three-dimensional forming.
2Area of stationary object
If conventional methods are used to manufacture three-dimensional objects with large surface areas and thin walls, then the objects can be produced, but mechanical failures occur at thin edges
Solution Approach 1:
The invention applies local quality by creating varying wall thicknesses within the same component using additive manufacturing. The layer-by-layer process allows for thicker material deposition at edges and thinner material in interior areas, providing local reinforcement where mechanical strength is needed while maintaining large surface areas and reducing overall material usage.
Solution Approach 2:
The invention uses composite materials by combining the flat plastic component with additional support structures or reinforcement elements during the additive manufacturing process. This creates a composite structure that maintains large surface areas while providing enhanced mechanical stability at critical edges and thin sections.
3Ease of manufacture
If complex processes like injection molding, deep drawing, and thermoforming are used, then three-dimensional objects can be manufactured, but the processes are prone to mechanical failure at thin edges
Solution Approach 1:
The invention replaces traditional mechanical forming processes (injection molding, deep drawing, thermoforming) with an additive manufacturing approach. Instead of using complex mechanical systems to form three-dimensional objects from flat sheets, the invention builds the objects layer-by-layer using material deposition and curing, eliminating the need for high-pressure mechanical forming and reducing structural failures at thin edges.
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 method enables the rapid and simplified production of three-dimensional objects with high stability and large surface areas, reducing mechanical failures at edges and allowing for customized designs, such as protective gear and lightweight structures, while maintaining structural integrity.
Implementation Method 1
Applying at least one curable polymer or curable reactive resin in flowable form as material sheets onto a flat base plate by means of a layer-by-layer forming process
Implementation Method 2
Forming the cured surface section into a three-dimensional object by means of deep drawing or thermoforming
Data Source
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AI summary
The invention relates to a method for producing a three-dimensional object, the outer surface of which comprises at least one surface segment that is created in that a surface segment in two-dimensional form is first produced on a flat base plate by means of an additive manufacturing method (layer-building shaping method), comprising the following steps: I) applying at least one curable polymer or curable reaction resin in flowable form as material webs to a flat base plate by means of a layer-building shaping method in order to create a first layer; II) applying a second layer to the first layer, which second layer is created by means of the same layer-building shaping method as in step I); III) optionally applying 1 to 198 further layers, which are created in accordance with step II), wherein in each case a new layer is applied to the previous layer; IV) curing the layers; V) detaching the cured surface segment from the flat base plate; and VI) shaping the cured surface segment into a three-dimensional object by means of deep-drawing or thermoforming; wherein at least one layer is created with a modulus of elasticity in the cured state of ≥ 500 MPa according to EN ISO 527-1 (last issue from April 1996, current ISO version from February 2012) by applying at least one curable polymer or curable reaction resin in flowable form as material webs to the particular substratum.