Layered Molding Process for Hollow 3D Objects
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Solution Overview
Problem
Existing manufacturing methods for three-dimensional objects face challenges with the use of plastics and rubber, including high maintenance costs, hazardous materials handling, distortion of printed images during heat treatment, and limited material versatility.
Innovation Solution
A method involving the use of elastic materials like ethylene vinyl acetate (EVA) covered with graphic-printed polyester fabric, where a silkscreen stencil is applied, and heat is used to set the design, allowing for the creation of hollow three-dimensional objects without the need for melting plastics or using hazardous liquids, and enabling accurate image retention without labor-intensive distortion correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If plastics and rubber are used for molding three-dimensional objects, then the objects can be produced in bulk with assembly-line techniques, but the manufacturing machines require high maintenance and repairs
Solution Approach 1:
The patent changes the physical state parameter of the working material from liquid (molten plastic/rubber) to solid (elastic foam sheets). This eliminates the need for high-temperature melting processes and hazardous liquid handling, thereby reducing machine maintenance requirements while preserving bulk production capability through automated vacuum forming
2Productivity
If plastics and rubber are used for molding three-dimensional objects, then the objects can be produced efficiently, but hazardous liquid materials must be handled
Solution Approach 1:
The patent changes the physical state from liquid to solid, using elastic foam sheets that are cut to size and adhered to molds. This eliminates hazardous liquid material handling while maintaining efficient production through automated vacuum forming processes
Solution Approach 2:
The patent uses disposable elastic foam sheets instead of reusable molten plastic/rubber systems. These foam sheets are cut to size, adhered to molds, and discarded after forming, eliminating the need for hazardous liquid material handling and complex recovery systems
3Shape
If heat treatment is applied to pre-stylized plastics, then the material can be deformed into three-dimensional shapes, but the printed image becomes distorted
Solution Approach 1:
The patent applies the stylized design to the elastic foam sheet before molding. Since the foam is not heated during forming, the printed image remains undistorted while the material is deformed into the desired three-dimensional shape
Solution Approach 2:
The patent changes the temperature parameter during forming, using cold or ambient temperature vacuum forming instead of heat treatment. This prevents distortion of the printed image while achieving the desired three-dimensional shape
4Ease of manufacture
If plastics are used for molding, then the material can be melted and deformed, but the process requires high temperatures
Solution Approach 1:
The patent changes the temperature parameter from high temperature melting to low temperature or ambient temperature vacuum forming. The elastic foam material is deformed using vacuum pressure rather than heat, eliminating the need for high-temperature processing
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 simplifies the production of three-dimensional objects by reducing maintenance needs, eliminating hazardous materials, and allowing for the creation of versatile, accurately designed products from a variety of materials with minimal labor and distortion issues.
Implementation Method 1
applying heat to set the printable material to the layer of fabric
Implementation Method 2
pressing an inside surface of a mold against the top surface of the elastic material
Data Source
AI summary
A fabrication method for producing a hollow three dimensional object is disclosed. The method includes disposing a layer of adhesive over a top surface of an elastic material, disposing a layer of fabric to the top surface of the elastic material, such that the layer of adhesive secures the layer of fabric to the elastic material, applying a silkscreen stencil to the outward facing side of the layer of fabric, applying printable material to the outward facing side of the layer of fabric via the silkscreen stencil, applying heat to set the printable material to the layer of fabric, pressing an inside surface of a mold against the top surface of the elastic material, so as to produce a first three-dimensional object having an open end and removing excess elastic material from a rim of the open end of the first three-dimensional object.