Additive Manufacturing Apparatus for Large Hollow Shells
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Solution Overview
Problem
The manufacturing of large 3D hollow objects, such as shells, faces challenges with deformation and material inefficiency due to the need for extensive support structures, which increase production time, material costs, and labor, while affecting the visual appearance and stability of the objects.
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, using materials like metal grids or dissolvable grids to reinforce the object and reduce the need for conventional support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If support structures are added to prevent shell deformation, then shell stability is improved, but production time and material consumption increase
Solution Approach 1:
The support material is dispensed in advance during the shell manufacturing process at critical locations identified by curvature analysis, rather than adding support structures afterward. This preliminary placement of support material prevents deformation as the shell is being built, eliminating the need for post-manufacturing support structure installation and subsequent removal, thereby reducing production time while maintaining shell stability.
Solution Approach 2:
The system analyzes the shell geometry to identify specific locations with high curvature change ratios where support is most needed. Support material is selectively dispensed only at these critical locations rather than uniformly across the entire shell, providing targeted stabilization that prevents deformation while minimizing unnecessary material consumption and production time.
2Stability of the object's composition
If support structures are added to prevent shell deformation, then shell stability is improved, but material costs increase
Solution Approach 1:
The system calculates curvature change ratios across the shell surface to identify specific critical locations where support is necessary. Support material is dispensed only at these localized areas with high curvature change ratios rather than uniformly across the entire shell, providing effective stabilization while minimizing material consumption.
Solution Approach 2:
The support material used is designed to be biodegradable or dissolvable, serving its temporary purpose during manufacturing to prevent deformation, then naturally degrading without requiring removal. This eliminates the need for permanent support structures and reduces material waste, as the support material breaks down into harmless substances.
3Stability of the object's composition
If support structures are added to prevent shell deformation, then shell stability is improved, but labor costs increase
Solution Approach 1:
The system automatically analyzes the shell's 3D model to calculate curvature change ratios and autonomously determines where support material should be dispensed. The apparatus performs the entire support placement process without human intervention, from geometric analysis to selective material dispensing, eliminating manual labor for support structure installation and removal while ensuring optimal stabilization.
Solution Approach 2:
The curvature analysis and support material dispensing locations are predetermined through automated calculation before manufacturing begins. This preliminary planning allows the system to automatically place support material at critical locations during manufacturing, eliminating the need for manual assessment and installation of support structures, thereby reducing labor requirements.
4Stability of the object's composition
If support structures are added to prevent shell deformation, then shell stability is improved, but visual appearance is degraded
Solution Approach 1:
The support material is designed to be biodegradable or dissolvable, serving its temporary function during manufacturing to prevent deformation, then naturally breaking down without trace. This eliminates the need for permanent support structures that would compromise the visual appearance of the finished shell, as no support elements remain to affect the aesthetic quality.
Solution Approach 2:
Support material is placed in advance during manufacturing at critical internal locations determined by curvature analysis. This preliminary placement provides necessary stabilization during the vulnerable manufacturing phase, and since the support material is temporary and degrades naturally, it does not remain to interfere with the final visual appearance of the shell.
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 necessity for extensive support structures, minimizing material consumption, production time, and labor costs, while maintaining the object's stability and visual integrity by dynamically dispensing support materials according to the object's geometry.
Implementation Method 1
Conversion of such materials into a solid form is typically performed by suitable actinic radiation and/or heat
Implementation Method 2
Conversion of such materials into a solid form is typically performed by suitable actinic radiation and/or heat
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3B
AI summary
The current document discloses an apparatus and method that support manufacture of large 3D hollow objects or shells with thin walls including curved surfaces with high and low curvature change ratio and alleviate or significantly reduce the need for support structures. Further to this, introduction of support structures becomes a function of the curved surface curvature change ratio.