3D Printing Elastic Objects Sensor Feedback
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Solution Overview
Problem
Conventional additive manufacturing methods, such as 3D printing, are inefficient for producing large quantities of objects due to time-consuming layer-by-layer construction and result in deformation of elastic materials during the printing process, making it difficult to maintain the desired contour and position of flexible or elastic objects.
Innovation Solution
The method involves using sensors to detect and monitor the contour and position of the 3D object within the support material, allowing for real-time adjustments of printing parameters and ensuring accurate shape retention by comparing actual and desired contours, using optical or ultrasonic sensors to collect data and transmit it to an electrical controller for processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If production material is introduced in a free-flowing state into support material for rapid additive manufacturing, then production speed is improved, but the production material deforms after introduction due to pressure changes and chemical reactions
Solution Approach 1:
The patent applies preliminary action by detecting the contour of the production material immediately after it is introduced into the support material, before deformations can occur. The sensor captures the initial contour data, and the electrical controller stores this information for later comparison with the final contour, enabling identification and compensation of deformations that occur during cross-linking and solidification.
Solution Approach 2:
The patent implements feedback by continuously monitoring the contour of the production material at multiple stages (after introduction, after cross-linking, after solidification) and comparing these measurements with the target contour. The electrical controller uses this feedback information to identify deviations and can adjust process parameters to compensate for deformations, ensuring the final object meets precision requirements.
2Adaptability or versatility
If elastic production material is used to create flexible 3-dimensional objects, then adaptability and functionality are improved, but the object collapses under gravity after removal from support material, making contour measurement difficult
Solution Approach 1:
The patent applies preliminary action by measuring and storing the contour of the production material while it is still in the support material, before the elastic object is removed and collapses under gravity. This preliminary contour data serves as a reference for comparing with the final deformed state, enabling accurate characterization of the elastic object's intended geometry despite subsequent collapse.
Solution Approach 2:
The support material acts as an intermediary that temporarily maintains the structural integrity of the elastic production material during the manufacturing process. The patent utilizes this intermediary state to perform contour measurements when the material is still supported, avoiding the need to measure the collapsed free-standing elastic object directly.
3Adaptability or versatility
If layer-by-layer construction method is used for additive manufacturing, then manufacturing flexibility is improved, but production time increases significantly for large objects
Solution Approach 1:
The patent applies segmentation by dividing the additive manufacturing process into distinct sequential stages: introducing production material in a free-flowing state, cross-linking, and solidification. This segmentation allows each stage to be optimized independently and enables parallel processing potential, reducing overall production time while maintaining the flexibility of layer-by-layer construction.
Solution Approach 2:
The patent implements continuity of useful action by eliminating idle time between manufacturing stages. The production material is continuously transformed from free-flowing state through cross-linking to solidification without interruption, and the sensor system continuously monitors the contour throughout the process, ensuring no measurement or processing time is lost.
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 enhances the precision and quality of 3D printing by maintaining the intended shape and position of elastic objects, reducing deformation and enabling the production of complex shapes with improved accuracy and consistency.
Implementation Method 1
The contour and/or the position of at least part of the 3-dimensional object within the support material is detected using at least one sensor
Implementation Method 2
using optical or ultrasonic sensors to collect data
Implementation Method 3
the production material is introduced into the desired positions within the support material in a free-flowing state... and then crosslinking, solidifying or curing there
Implementation Method 4
crosslinking, solidifying or curing there
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method for producing a 3-dimensional object (6) by means of an additive manufacturing process in which at least one manufacturing material in a flowable state is introduced into a support material (4) from at least one insertion opening of an insertion needle and then hardens, wherein the manufacturing material is elastic after hardening, wherein the contour and/or the position of at least one part of the 3-dimensional object within the support material is detected by means of at least one sensor (8, 14).