Additive Manufacturing Feed-In Needle Layer Machining
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Solution Overview
Problem
Existing additive manufacturing processes, such as 3D printing, are inefficient for producing large quantities of three-dimensional objects due to the time-consuming nature of building up thin layers and often result in inadequate bonding and surface quality between layers, especially with certain material combinations.
Innovation Solution
The method involves using a feed-in needle with a tool that machines the previous layer when introducing a new layer of manufacturing material, improving adhesion and surface contact without increasing hydrostatic pressure, allowing for thicker layers and smoother surfaces by machining and mixing the layers during the additive process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional 3D printing methods are used to build up thin layers, then manufacturing precision is improved, but productivity deteriorates due to time-consuming production
Solution Approach 1:
The patent changes the fundamental parameter of layer thickness from conventional thin layers (few micrometers) to thick layers (several millimeters). This is achieved by introducing manufacturing material in a free-flowing state into a support material, allowing layers to be deposited much thicker than traditional 3D printing while maintaining adequate bonding through the unique material interaction mechanism.
Solution Approach 2:
The support material acts as an intermediary medium that enables thick layer deposition. The manufacturing material is introduced into the support material, which provides structural support while allowing the manufacturing material to flow and bond effectively. This intermediary system enables the contradiction resolution by decoupling the support function from the manufacturing material itself.
2Productivity
If thicker layers are used to reduce production time, then productivity is improved, but manufacturing precision deteriorates due to inadequate bonding and poor surface quality
Solution Approach 1:
The patent changes the bonding mechanism parameter by utilizing the interaction between free-flowing manufacturing material and support material. Instead of relying on traditional layer adhesion methods that fail with thick layers, the system uses the support material to enable proper bonding and surface smoothing during the free-flowing state, achieving both thick layers and high bonding quality.
3Manufacturing precision
If material pressure is increased to improve layer bonding, then manufacturing precision is improved, but device complexity increases due to additional pressure control systems
Solution Approach 1:
The system uses self-service by utilizing the natural density ratio between manufacturing material and support material. The manufacturing material remains in the desired position automatically due to density differences, eliminating the need for complex pressure control systems. The bonding is achieved through the material properties and flow dynamics rather than external pressure application.
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 bonding between layers, reduces production time for large objects, and improves surface quality, making it suitable for producing flexible or elastic objects and biocompatible materials like silicones, even for orthopaedic devices.
Implementation Method 1
Due to the density ratios between the manufacturing material and the support material, the manufacturing material that has been introduced remains in the respective position
Implementation Method 2
subsequently cross-linking, setting or curing it there
Data Source
AI summary
The invention relates to a method for producing a three-dimensional objects by means of an additive manufacturing process in which at least one manufacturing material is fed in a free-flowing state from at least one feed-in opening of at least one feed-in needle into a supporting material and then cured, the manufacturing material being introduced in multiple layers one after the other, wherein the feed-in needle comprises at least one tool by which at least one previous layer is machined when a current layer of the manufacturing material is introduced.