Composite-Based Additive Manufacturing Using Digital Printing
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Solution Overview
Problem
Existing three-dimensional fabrication methods, such as injection molding and conventional additive manufacturing, face challenges including high tooling costs, slow production times, limited material selection, and geometric restrictions, which hinder the efficient creation of complex objects with moving parts and composite materials.
Innovation Solution
The CBAM process leverages conventional printing technologies, like offset lithography and inkjet printing, to create three-dimensional objects by printing individual pages with digital methods, eliminating the need for expensive tooling and allowing for faster production with greater geometric flexibility and material variety, using bonding agents like polymer powders and automated folding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding is used for mass production, then production speed and cost efficiency are improved, but tooling costs and lead time increase significantly
Solution Approach 1:
The patent uses digital printing to create physical copies of 3D object layers directly from digital models, eliminating the need for physical molds. Each layer is printed as a copy of the digital design, allowing rapid iteration and production without tooling lead times
Solution Approach 2:
The patent replaces the mechanical mold-making and mold-closing system with a digital printing system. Instead of physically creating and using molds, the system uses digital files to directly deposit material layer by layer, substituting mechanical tooling with digital fabrication
2Productivity
If injection molding is used, then mass production capability is improved, but geometric flexibility and material selection are restricted
Solution Approach 1:
The patent enables dynamic adaptation of the manufacturing process by allowing digital model modifications without physical tooling changes. The system can rapidly adjust geometries, incorporate moving parts, and change materials by simply updating the digital file, providing geometric flexibility while maintaining production capability
Solution Approach 2:
The patent extends material selection to include composite materials and high-performance polymers that were difficult or impossible to process with traditional injection molding. The layer-by-layer printing approach allows incorporation of diverse materials including carbon fiber composites and specialized polymers
3Ease of manufacture
If conventional additive manufacturing is used, then tooling costs are reduced, but production speed and material properties deteriorate
Solution Approach 1:
The patent extracts the slowest step from conventional additive manufacturing (sequential layer printing) by using digital printing technology that can rapidly deposit multiple layers simultaneously or in parallel, maintaining the cost advantage while dramatically improving production speed
Solution Approach 2:
The patent changes the physical parameters of the printing process by using digital printing methods that deposit material more rapidly and with better control, improving both production speed and material properties while keeping tooling costs low
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 mass production of complex three-dimensional objects in hours rather than months, reducing tooling costs and eliminating mold-related issues, while improving material properties and geometric possibilities, including the use of high-performance materials like carbon fiber.
Implementation Method 1
Offset lithography is a particularly mature and suitable technology for mass production of paper items
Implementation Method 2
The approach is based on the CBAM process ('composite-based additive manufacturing'), except that it takes advantage of conventional printing technology
Implementation Method 3
using bonding agents like polymer powders
Implementation Method 4
The folded item can then be compressed and heated to permit fusing between layers
Implementation Method 5
compressed and heated to permit fusing between layers
Data Source
AI summary
An additive manufacturing method and apparatus is described for the printing of three-dimensional (3D) objects. The approach is based on a composite-based additive manufacturing process, except it uses commercial printing methods to achieve even higher speed and throughput. By using the invention, a prototyping and/or production process may be completed in hours rather than months, and the risks and problems of molds is eliminated. There is substantial improvement in the number and type of geometries that can be produced compared to injection molding, and the range of materials is enlarged as are the material properties. The method involves printing a substrate having at least one sheet using a printing technology, and stacking or folding the at least one sheet to form multiple layers consistent with that formed by a 3D model. The printing step is done using a printing technology such as flexography, lithography, offset, gravure, waterless printing, and silkscreen.