3D Mold Manufacturing Apparatus with Bulge Detection and Layer Thickness Adjustment
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Solution Overview
Problem
Existing three-dimensional mold object manufacturing techniques face challenges with dimensional precision and productivity due to issues like missing portions and bulges caused by foreign matter, which are difficult to address without reducing productivity through extensive milling and planarizing processes.
Innovation Solution
A three-dimensional mold object manufacturing apparatus equipped with a bulge detecting unit and layer forming section that adjusts layer thickness based on detected bulges, using a composition including particles, binding liquid, and energy rays to form layers with improved precision and prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a powder layer with smaller thickness is formed using powder particles, then the resolution and detail of the three dimensional mold object are improved, but dimensional precision is reduced and defects such as missing portions are generated due to bulges from foreign matter
Solution Approach 1:
The patent applies preliminary action by detecting bulges on the powder layer surface before forming subsequent layers. The bulge detection unit identifies foreign matter or surface irregularities, and the control unit pre-adjusts the thickness of the next powder layer to compensate for detected bulges, preventing defects before they occur rather than correcting them afterward
Solution Approach 2:
The patent implements feedback control by using the bulge detection unit to monitor the powder layer surface condition and feeding this information back to the control unit, which then adjusts the powder layer thickness in real-time based on the detected bulge height, creating a closed-loop control system that maintains dimensional precision
2Manufacturing precision
If a processing means with a milling head is used to remove bulges from the powder layer, then dimensional precision is improved, but productivity is remarkably reduced due to the need to remove numerous bulges individually and re-planarize the layer
Solution Approach 1:
Instead of removing bulges after they form, the patent takes preliminary action by detecting bulges and adjusting subsequent powder layer thickness to compensate for them. This preventive approach eliminates the need for time-consuming milling and re-planarizing operations, maintaining high productivity while ensuring surface quality
Solution Approach 2:
The patent replaces the mechanical bulge removal system (milling head) with a non-contact optical detection system (bulge detection unit) and a control system that adjusts powder deposition. This substitution eliminates the need for mechanical intervention to remove bulges, significantly improving manufacturing speed
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 apparatus effectively prevents defects and enhances dimensional precision of three-dimensional mold objects by adjusting layer thickness and applying binding liquid and energy rays, improving productivity and mechanical strength while avoiding the need for extensive bulge removal and re-planarizing processes.
Implementation Method 1
a binding liquid applying unit configured and arranged to apply a binding liquid
Implementation Method 2
an energy rays applying unit configured and arranged to apply energy rays
Data Source
AI summary
A three dimensional mold object manufacturing apparatus is adapted to manufacture a three dimensional mold object by repeatedly forming and layering layers using a composition including particles. The apparatus includes a layer forming section configured to form the layers using the composition and a bulge detecting unit configured to detect a bulge on the layers. When the bulge detecting unit detects the bulge with a height equal to or more than a predetermined height formed on one of the layers, the layer forming section is configured and arranged to adjust a thickness of a subsequent one of the layers, which is provided directly on the one of the layers where the bulge is detected.