3D Object Production via Flat Layer Segmentation
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Solution Overview
Problem
Current methods for producing three-dimensional objects, such as shoes, are lengthy and require high room temperatures, making them inefficient for creating objects with large surfaces and low thickness, like shoe uppers or protective gear.
Innovation Solution
A method involving the conversion of three-dimensional objects into a continuous, flat two-dimensional shape using additive manufacturing, where curable polymers are applied in layers, hardened, and then shaped by bending, folding, or thermoforming, followed by fixation through welding, gluing, or other means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If three-dimensional objects are produced directly using additive manufacturing processes, then the production is simplified, but the production time is excessive and high room temperatures are required
Solution Approach 1:
The manufacturing process is divided into two distinct phases: first producing flat two-dimensional components using additive manufacturing, then assembling these components into three-dimensional objects. This segmentation allows each phase to be optimized independently, reducing overall production time while maintaining simplicity.
Solution Approach 2:
The invention transitions from directly manufacturing three-dimensional objects to first creating two-dimensional flat components, then forming them into three-dimensional shapes through bending and assembly. This dimensional approach eliminates the time-consuming layer-by-layer building of complex 3D structures.
2Ease of manufacture
If three-dimensional objects are produced directly using additive manufacturing processes, then the manufacturing is simplified, but high room temperatures are required
Solution Approach 1:
By separating the manufacturing into flat component production and subsequent assembly, the process avoids the need for high temperatures during the additive manufacturing phase, as flat components require less thermal energy to process than complex three-dimensional structures.
Solution Approach 2:
Producing two-dimensional flat components instead of directly manufacturing three-dimensional objects reduces the thermal requirements, as the additive manufacturing process for flat layers requires lower temperatures and less energy accumulation.
3Ease of manufacture
If entire shoes are printed using 3D printing, then complete objects are produced, but the production is time-consuming
Solution Approach 1:
The shoe manufacturing process is segmented into producing flat upper components and soles separately through additive manufacturing, then assembling them into complete shoes. This avoids the time-consuming process of printing entire three-dimensional shoe structures layer by layer.
Solution Approach 2:
The invention produces flat two-dimensional shoe components that are then formed into three-dimensional shapes through bending and assembly, dramatically reducing the additive manufacturing time compared to directly printing complete three-dimensional shoes.
4Shape
If objects with large surface area and low thickness are produced using conventional additive manufacturing, then the desired shape is achieved, but the production is lengthy
Solution Approach 1:
The invention directly produces flat two-dimensional components with large surface areas through additive manufacturing, then forms these into three-dimensional objects with the desired large surface area and low thickness characteristics. This approach is much faster than directly printing the final three-dimensional shape.
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 method allows for the faster and simplified production of three-dimensional objects with large surfaces and low thickness, reducing production time and temperature requirements.
Implementation Method 1
applying at least one curable polymer or curable reactive resin... curing the layers
Implementation Method 2
shaping by placing the two-dimensional surface section on a strip, thermoforming in the presence of at least one thermoformable polymer in a two-dimensional surface section
Data Source
Figure 1~3
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Figure 7~8
AI summary
The invention relates to a method for producing a three-dimensional object, the outer surface of which has at least one surface section that is generated in that, by means of an additive production method (layer-building forming method), initially a surface section is produced on a flat base plate (5) in two-dimensional form, comprising the following steps: I) applying at least one curable polymer or curable reaction resin with a respective elastic modulus according to DIN 53504 (effective: 18.04.2015) in the cured state, of < 250 MPa in fluid form, as material webs onto a flat base plate (5) by means of a layer-building forming method in order to produce a first layer (6); II) applying a second layer (7) onto the first layer (6) by means of the same or another layer-building forming method, like in step I); III) optionally applying between 1 and 48 additional layers according to step II), wherein each new layer is applied onto the respective previous layer; IV) curing the layers; V) releasing the cured surface section from the flat base plate (5); VI) forming the cured surface section into a three-dimensional object; and VII) securing the three-dimensional object.