Laminated Molding of Internal Spaces Without Support Removal
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Solution Overview
Problem
The existing methods for manufacturing additively-manufactured objects with internal spaces face challenges in removing support materials, which requires time and effort, and in cases of narrow or closed spaces, the removal becomes difficult or impractical.
Innovation Solution
A method involving an additively-manufactured object manufacturing system that uses a welding robot with a torch to deposit weld beads, forming side and connecting wall portions, and a closing wall portion to enclose the internal space, eliminating the need for support material removal by creating a self-contained structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If support material is used to build internal spaces, then built objects with internal spaces can be manufactured, but the support material removal process requires time and effort
Solution Approach 1:
The invention extracts and removes the support material structure from the manufacturing process entirely. Instead of using support material to build internal spaces, the method directly forms the internal space by controlling the deposition path to deposit material only on the outer surface, eliminating the need for support material and its subsequent removal
Solution Approach 2:
The invention inverts the conventional approach by not building internal spaces with support material and then removing it, but rather by directly forming the internal space through controlled deposition on the outer surface from the beginning, reversing the sequence and methodology of creation and removal
2Ease of manufacture
If support material is used for closed or narrow internal spaces, then built objects with complex internal spaces can be manufactured, but tool access for removal becomes difficult or impossible
Solution Approach 1:
The invention extracts the support material concept entirely from the process. By controlling the deposition path to deposit material only on the outer surface, the internal space is formed directly without requiring support material, eliminating the accessibility problem entirely
Solution Approach 2:
The invention performs preliminary action by planning and executing the deposition path in advance to directly form the internal space structure without support material. The deposition path is carefully designed from the beginning to deposit material only where needed on the outer surface, pre-establishing the internal space geometry
3Ease of operation
If support material with fluidity is used for narrow open spaces, then support material can be removed, but the material is not easy to handle and removal still takes time
Solution Approach 1:
The invention extracts and eliminates the support material from the manufacturing process entirely. By controlling deposition to occur only on the outer surface, the internal space is formed directly without any support material, removing the need for handling and removal operations
Solution Approach 2:
The invention applies self-service by having the deposition process itself create the internal space structure without requiring separate support material and removal operations. The controlled deposition path automatically forms the desired geometry, making the system self-sufficient
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 easy manufacture of additively-manufactured objects with internal spaces without the need for support material removal, ensuring efficient production and preventing issues like molten metal penetration, thereby producing high-strength objects with internal spaces.
Implementation Method 1
A 3D printer using a metal material melts a metal powder or a metal wire by using a heat source such as a laser or an arc, and deposits the molten metal to build a built object
Implementation Method 2
As a technique for building such a built object by welding, it is known to perform weaving welding in which welding is performed by swinging a torch left and right with respect to a welding direction
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
This method includes: a laminated molding step in which a welding bead obtained by melting and solidifying a filler is laminated, and an internal space surrounded by the welding bead is formed to mold a laminated article, the internal space having an opening along the direction in which the welding bead is formed; and a blocking step in which an edge part of the opening is continuously blocked by the welding bead to form a blocking wall part. In the laminated molding step, the opening is formed so as to have a width dimension greater than the bead width of the welding bead. In the blocking step, the blocking wall part, which has a width dimension greater than the bead width, is formed by the welding bead to block the opening.