Additive Manufacturing of Large Hollow Shells with Embedded Supports
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Solution Overview
Problem
The manufacturing of large 3D hollow objects, such as shells, often requires extensive support structures to prevent deformation, which increases material costs, production time, and labor, while also affecting the visual appearance and weight of the final product.
Innovation Solution
An apparatus and method for additive manufacturing that includes a 3D hollow object material deposition module, a solidifying module, and a support material dispensing module, which dispenses support material based on the curvature change ratio and angle of the object's walls, allowing for reduced reliance on external supports and integrating support materials into the object's structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If support structures are added to prevent deformation of large shells, then structural stability is improved, but material consumption increases
Solution Approach 1:
The support structures are merged with the shell structure by integrating them into the hollow inner space. The support structures become part of the overall object, combining the shell material with support material to create a unified structure that provides both containment and structural stability.
Solution Approach 2:
The support structures are nested within the hollow inner space of the shell. This nesting approach allows the support structures to be positioned inside the shell without adding external bulk, thereby providing structural stability while minimizing additional material consumption.
2Manufacturing precision
If multiple support structures are constructed to prevent shell deformation, then manufacturing precision is improved, but production time increases
Solution Approach 1:
The support structures are constructed in advance during the additive manufacturing process itself, before the shell is removed from the manufacturing apparatus. This preliminary construction of support structures eliminates the need for time-consuming post-manufacturing assembly operations.
Solution Approach 2:
The additive manufacturing apparatus automatically constructs the support structures as part of the manufacturing process. The system serves itself by integrating support structure fabrication into the shell manufacturing workflow, eliminating the need for separate manual support installation steps.
3Strength
If support structures are added to hollow shells, then structural strength is improved, but visual appearance deteriorates
Solution Approach 1:
The support structures are nested within the hollow inner space of the shell, making them invisible from the exterior. This nesting approach allows the support structures to provide necessary structural strength while remaining hidden, thus preserving the visual appearance of the shell.
4Reliability
If extensive support structures are used in large shell manufacturing, then reliability is improved, but device complexity increases
Solution Approach 1:
The additive manufacturing apparatus is designed to perform multiple functions: it manufactures both the shell and the support structures in a single integrated process. This multi-functionality reduces the need for separate devices or processes for support structure fabrication, thereby reducing overall device complexity while maintaining manufacturing reliability.
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 reduces the need for additional support structures, decreases material consumption, shortens manufacturing time, and maintains the object's visual integrity by embedding support materials within the object, thereby lowering costs and improving production efficiency.
Implementation Method 1
Manufacture of three dimensional (3D) models or objects is an additive manufacturing process by means of which a computer generated 3D model is converted into a physical object. The process, sometimes termed stereo-lithography, involves generation of a plurality of material layers of different or identical shapes that are laid down or deposited
Implementation Method 2
Conversion of such materials into a solid form is typically performed by suitable actinic radiation and/or heat
Implementation Method 3
Conversion of such materials into a solid form is typically performed by suitable actinic radiation and/or heat
Data Source
AI summary
An apparatus for additive manufacturing of large 3D hollow objects with thin walls, includes a 3D hollow object material deposition module configured to deposit a portion of material forming at least a layer of a 3D hollow object wall; a 3D hollow object material solidifying module configured to solidify at least the portion of material forming at least a layer of the 3D hollow object wall; and a support material dispensing module configured to dispense a support material across a cross section of the 3D hollow object wall. The support material is dispensed separately prior to or concurrently with the deposition of the portion of material forming at least a layer of a 3D hollow object wall.