Continuous 3D Printing via Integrated Bonding and Unpacking
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Solution Overview
Problem
Existing 3D printing methods require multiple discrete steps and high equipment costs, with the removal of unbound particulate material being a separate process after the build process is completed, limiting continuous operation and efficiency.
Innovation Solution
A method and device for continuous production of three-dimensional objects using computer-provided data, where material is deposited in layers and selectively solidified within a process chamber, allowing continuous conveyance and simultaneous implementation of multiple work steps without a lowerable build platform, enabling continuous operation and simultaneous unpacking of objects during the build process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If material is deposited in layers and selectively solidified using a bonding apparatus in a process chamber, then manufacturing precision and productivity are improved through continuous operation, but device complexity increases due to the integration of multiple work steps
Solution Approach 1:
The patent combines multiple work steps (material deposition, selective solidification, and object unpacking) into a single integrated process chamber. The bonding apparatus performs both solidification and unpacking functions within the same chamber, eliminating the need for separate processing stations and enabling continuous operation without interrupting the build process.
Solution Approach 2:
The process chamber is designed to serve multiple functions: it acts as both the build chamber for selective solidification and the unpacking chamber for removing unbound particulate material. This multi-functional design allows the same space to handle different stages of the manufacturing process, improving productivity while managing device complexity.
2Device complexity
If unbound particulate material removal is performed as a separate process after build completion, then device complexity is reduced, but productivity deteriorates due to process interruption
Solution Approach 1:
The patent implements continuous operation by performing the unpacking of unbound particulate material simultaneously with the ongoing build process. While new layers are being deposited and solidified, the bonding apparatus concurrently removes unbound material from previously deposited layers, eliminating idle time and maintaining continuous productive action throughout the manufacturing cycle.
Solution Approach 2:
The unpacking of unbound particulate material is performed preliminarily during the build process rather than waiting until completion. By removing loose material as layers are deposited, the system prepares objects for final extraction in advance, enabling continuous operation without interrupting the build process for post-processing.
3Manufacturing precision
If a lowerable build platform is used for layer deposition, then manufacturing precision is improved through controlled positioning, but ease of operation deteriorates due to limited continuous conveyance
Solution Approach 1:
The patent transitions from a static lowerable build platform to a dynamic system where the build platform remains stationary and material is conveyed continuously through the process chamber. This dynamic approach allows uninterrupted material flow while maintaining positioning accuracy through controlled material deposition and conveyance mechanisms rather than platform movement.
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 simplifies the construction of the device, reduces equipment costs, and allows for continuous and controlled material handling, enabling the production of complex components without interrupting the build process, with improved stability and reduced material buffering requirements.
Implementation Method 1
a bonding apparatus for selectively bonding and/or a solidification apparatus for selectively solidifying in the process chamber
Data Source
AI summary
The present invention relates to a method and a device for producing three-dimensional objects based on computer-provided data. Material is extruded on a surface of a workpiece (e.g., in two-dimensions). The workpiece is then moved incrementally so that additional material can be extruded on the new surface of the work piece. These steps are repeated until the 3-dimensional object is completed. The present invention also relates to a device including an extruder system for extruding a build material in multiple directions on a surface of a workpiece, and a conveying component for moving the workpiece incrementally for extruding additional material on the new surface. The method and device preferably allows for the continuous construction of three-dimensional objects.