3D Lamination Molding Quality Control via Surface Projection Analysis
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Solution Overview
Problem
Defects such as voids often occur in three-dimensional molded objects during the lamination molding process, and there is a correlation between the internal state of solidified layers and their surface state, making it difficult to determine the quality of the molded object in real-time.
Innovation Solution
A method and apparatus that form a solidified layer by irradiating a material layer with a laser or electron beam, measuring surface projections using a meter, and calculating their heights, area, or number to determine the molded state by comparing these metrics against predetermined thresholds, allowing for continuous assessment of the molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If lamination molding is performed by irradiating material layer with laser beam or electron beam, then three-dimensional molded object can be produced, but defects such as voids occur during molding and quality determination is difficult
Solution Approach 1:
The patent applies optical measurement to detect surface projections on solidified layers. By measuring the height, area, or presence of projections on the surface, the system indirectly determines the internal molded state including void formation. This optical detection method enables real-time quality assessment without requiring internal inspection, resolving the contradiction between production capability and quality determination difficulty
Solution Approach 2:
The patent implements a feedback mechanism where surface projection measurements are continuously taken during lamination molding, compared against predetermined thresholds, and used to determine molded state quality. This real-time feedback enables dynamic quality monitoring and control, allowing the system to detect and respond to defects such as voids during the molding process rather than only after completion
2Manufacturing precision
If surface state observation is used to determine molded state, then quality assessment becomes possible, but additional measurement steps increase process complexity
Solution Approach 1:
The patent makes the measurement system multi-functional by using surface projection detection for multiple purposes: determining molded state quality, detecting void formation, and monitoring internal layer conditions. By consolidating these quality assessment functions into a single measurement approach, the system achieves comprehensive quality control without proportionally increasing device complexity
Solution Approach 2:
The solidified layer itself serves as the measurement target - its surface projections naturally form as indicators of internal molded state. The system leverages these self-formed surface features rather than requiring separate internal sensors or complex inspection equipment, enabling quality determination through simple surface measurement that reduces overall system complexity
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 the production of highly accurate three-dimensional molded objects by determining the quality of the molded state during the process, preventing defects and ensuring high-quality end products.
Implementation Method 1
forming a solidified layer by irradiating an irradiation region of a material layer with a laser beam or an electron beam
Implementation Method 2
formation of a solidified layer by irradiation of the material layer with a beam, such as a laser beam or electron beam
Data Source
AI summary
A method for producing a three-dimensional molded object includes forming a solidified layer by irradiating an irradiation region of a material layer with a laser beam or an electron beam, obtaining data about projections having a height higher than a predetermined value formed on a surface of the solidified layer, calculating heights of the projections, areas of the projections, or the number of the projections based on the data, and determining a molded state of the solidified layer by making a comparison between the calculated heights of the projections and a first threshold relating to heights of the projections, between the calculated areas of the projections and a second threshold relating to an areas of the projections, or between the calculated number of the projections and a third threshold relating to the number of the projections.