Layer-by-Layer Forming with Reinforcing Elements
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Solution Overview
Problem
Existing methods for three-dimensional layer-by-layer object formation lack the structural strength required for manufacturing large, functional objects, limiting their use to visualization and prototyping.
Innovation Solution
A method and device that incorporate alternating layers of bulk material and binding agent, with the addition of reinforcing elements such as carbon fiber, metal, or thermoplastic materials applied in specific patterns to enhance structural reinforcement, allowing for the creation of large, functional objects through techniques like three-dimensional printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If layer-by-layer free forming techniques are used to manufacture large objects, then productivity and manufacturing capability are improved, but structural strength is insufficient
Solution Approach 1:
The patent applies composite materials by combining bulk material layers with reinforcing elements (such as fibers, meshes, or structural shapes) to create a composite structure that maintains the additive manufacturing capability while significantly improving structural strength. The reinforcing elements are integrated into the bulk material layers to form a composite object that meets both productivity and strength requirements.
2Ease of manufacture
If only bulk material and binding agent are used, then ease of manufacture is improved, but structural reinforcement is insufficient
Solution Approach 1:
The patent introduces reinforcing elements as a third component to create a composite structure consisting of bulk material, binding agent, and reinforcing elements. This composite approach maintains ease of manufacture through automated layer-by-layer deposition while providing the necessary structural reinforcement for functional objects.
3Strength
If reinforcing elements are added to bulk material layers, then structural strength is improved, but device complexity increases
Solution Approach 1:
The patent segments the object into discrete layers, with each layer potentially containing different combinations of bulk material and reinforcing elements. This segmentation allows for optimized structural design in different regions while maintaining a systematic manufacturing process that can be automated, thereby managing device complexity.
Solution Approach 2:
The patent enables dynamic adjustment of reinforcing element patterns, types, and distributions based on structural requirements of different object regions. This dynamic approach allows the manufacturing system to adapt to varying strength requirements without requiring a completely different device configuration, thus managing complexity while providing tailored structural reinforcement.
Data Source
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AI summary
Embodiments herein relate to methods and devices for layer-by layer forming objects and to objects manufactured in accordance with such methods and devices. The method comprises the steps of distributing (101) a layer of bulk material, applying (102) a binding agent applying (103) at least one reinforcing element onto the layer of bulk material or binding agent, wherein the reinforcing element is adapted to structurally reinforce the object, wherein the steps of distributing (101) a layer of bulk material, applying (102) a binding agent and applying (103) at least one reinforcing element are alternatively repeated a desired number of times to form the object, and wherein adjacent layers of bulk material are bonded by means of the binding agent. The device comprises a bulk material distributing unit (10) for distributing a layer of bulk material, a binding agent applying unit (11) for applying a binding agent, a reinforcing element applying unit (12) for applying at least one reinforcing element onto the layer of bulk material or binding agent.