Dynamic Molding Bed With Adjustable Rods for Complex Surface Forming
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Solution Overview
Problem
Custom design and construction of themed structures in amusement parks, such as artificial rockwork panels, are cumbersome, time-consuming, and costly, limiting scalability and production speed due to the need for extensive customization and use of conventional building materials.
Innovation Solution
A dynamic molding bed assembly with a passive rod assembly that includes independently adjustable rods actuated by an external device, allowing for the formation of non-planar surfaces using additive construction methods without sacrificial support materials, enabling the creation of themed structures with irregular shapes and surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional building techniques and materials are used to construct themed structures, then structural strength and stability are ensured, but the construction process becomes complex and time-consuming
Solution Approach 1:
The patent uses digital 3D models as copies of the desired themed structures to guide the additive construction process. The digital models contain all geometric and structural information needed for construction, eliminating the need for complex manual planning and measurements while maintaining design accuracy
Solution Approach 2:
The system dynamically adjusts construction parameters such as rod stroke lengths, material deposition rates, and layer thickness during the additive construction process. This allows real-time optimization of construction speed and complexity management without compromising structural integrity
2Adaptability or versatility
If custom-built components are manufactured for themed environments, then unique shapes and surfaces are achieved, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent employs a dynamic molding bed with adjustable rods that can be repositioned during the construction process. This dynamic capability allows the system to adapt to different custom designs without requiring separate tooling or fixtures for each component, significantly reducing manufacturing time while maintaining versatility
Solution Approach 2:
The themed structures are constructed layer-by-layer using additive manufacturing, dividing the custom component into multiple manageable layers. This segmentation allows for efficient manufacturing of complex custom shapes without requiring complete custom tooling for each unique component
3Loss of substance
If additive construction methods are used without sacrificial support materials, then material waste is reduced, but the ability to form complex non-planar surfaces is limited
Solution Approach 1:
The patent introduces a dynamic molding bed with adjustable rods as an intermediary support structure during additive construction. These rods provide temporary support for overhangs and complex geometries without requiring sacrificial materials, enabling the formation of complex non-planar surfaces while minimizing material waste
Solution Approach 2:
The adjustable rods on the molding bed are repositioned and removed as the structure is built layer-by-layer, with each layer providing support for subsequent layers. This self-service approach eliminates the need for permanent sacrificial support materials while enabling complex surface formation
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
Enables efficient, scalable, and less burdensome customization of themed structures by dynamically reconfiguring rods to form complex surfaces, supporting additive manufacturing processes that enhance production speed and reduce material waste.
Implementation Method 1
The spring is used to generate tension based on a stroke length position of the individual rod
Data Source
AI summary
A system is provided that includes a dynamic molding bed assembly. The dynamic molding bed assembly includes a table frame, a passive rod assembly, an actuator and a controller. The passive rod assembly includes a plurality of rods, wherein each individual rod of the plurality of rods is independently adjusted to change a stroke length position relative to the table frame. The actuator couples to at least one individual rod of the plurality of rods to adjust the stroke length position of the at least one individual rod of the plurality of rods based on control instructions. The controller generates the control instructions to adjust the stroke length position and activates the passive rod assembly to secure at least one individual rod of the plurality of rods to the stroke length position.