Additive Manufacturing of Integrated Forming and Drying Modules
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Solution Overview
Problem
Existing methods for producing containers using pulp face challenges in creating complex shapes and require restarting the manufacturing process for geometry variations, making them inefficient and resource-intensive.
Innovation Solution
The use of additive manufacturing processes, such as 3D printing, to produce molding and drying modules that can form and dry containers with fibers, allowing for customizable shapes and materials like metal or plastic, with features like support structures and adjustable pore sizes for optimal fiber alignment and water drainage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional multi-part molds are used for forming containers using pulp, then the manufacturing process can produce containers, but it becomes difficult to manufacture complexly structured molds and requires restarting the manufacturing process when geometry varies
Solution Approach 1:
The patent combines the forming module and drying module into a single integrated mold structure. The forming module includes a cavity for shaping the pulp, while the drying module includes heating channels and drying cavities integrated within the same mold body. This integration eliminates the need for separate forming and drying operations, allowing geometry variations to be accommodated without restarting the entire manufacturing process.
Solution Approach 2:
The patent utilizes additive manufacturing technology to produce molds with varying geometric parameters. The mold can be digitally designed and manufactured with different cavity shapes, sizes, and configurations by changing the digital model parameters. This allows rapid adaptation to geometry variations without complex manual manufacturing processes.
2Reliability
If separate forming and drying modules are used, then each function can be optimized, but the infrastructure becomes more complex and requires multiple types of housings
Solution Approach 1:
The forming module and drying module are merged into a single integrated structure where the forming cavity and drying channels coexist within the same mold body. The forming module compresses the pulp between an outer mold and an inner mold, while the drying module simultaneously or sequentially removes moisture through integrated heating channels. This eliminates the need for separate housings and reduces infrastructure complexity.
Solution Approach 2:
The integrated mold serves multiple functions: forming the container shape, heating the molded container, and drying the moisture. The same mold structure performs all these operations without requiring separate dedicated equipment, making the system more universal and reducing infrastructure requirements.
3Adaptability or versatility
If additive manufacturing is used to produce forming and drying modules, then customizable shapes and complex structures can be achieved, but new manufacturing processes are required
Solution Approach 1:
The patent replaces traditional mechanical manufacturing processes (turning, milling, deep drawing) with additive manufacturing technology. Instead of removing material or forming it through mechanical forces, the mold structures are built layer-by-layer using 3D printing. This enables complex geometries and customizations that would be difficult or impossible to achieve with conventional manufacturing.
Solution Approach 2:
Additive manufacturing allows for local optimization of the mold structure. Different regions of the mold can have different properties (e.g., varying wall thickness, porosity, or material composition) tailored to specific functional requirements. For example, certain areas can be designed with enhanced heat conduction for drying, while other areas maintain structural integrity.
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 containers with complex shapes using biodegradable and sustainable fibers, offering increased functionality, reduced material waste, and simplified infrastructure by using a single module for both molding and drying, while ensuring mechanical and temperature resistance.
Implementation Method 1
at least a part of the forming and/or drying module is produced by means of an additive manufacturing process, for example by means of 3D printing
Implementation Method 2
The support structure can comprise pores and/or passages and/or channels
Implementation Method 3
a second cavity for receiving and conveying water pressed from the pulp to an outlet
Implementation Method 4
channels for heating media and channels for discharging water and/or steam can be provided in the further porous wall
Data Source
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AI summary
The invention relates to a method for producing mold and/or drying modules for the production of fiber-containing containers using the mold and/or drying modules, wherein the method comprises producing a mold and/or drying module (14), wherein at least a part of the mold and/or drying module is produced using an additive manufacturing process, for example by means of 3D printing.The invention further relates to an apparatus for carrying out the method for producing forming and/or drying modules for the production of fiber-containing containers, a forming and/or drying module produced by means of this method, a method for producing a fiber-containing container using a forming and/or drying module produced by means of the method for producing forming and/or drying modules for the production of fiber-containing containers, and an apparatus for producing fiber-containing containers using fiber-containing pulp, wherein the apparatus comprises one or more of the forming and/or drying modules.