3D Molding System Mixed Material Layer Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing three-dimensional molding techniques face challenges in laminating layers made of different materials, as certain material combinations are difficult to bond, and existing methods cannot create regions within a layer with varying materials.
Innovation Solution
A molding system that generates modified slice data to mix materials in regions where lamination is difficult, ensuring that layers of the same type and different types are present in a mixed pattern, facilitating bonding between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If layers of different materials are laminated together to manufacture a molded object with varying physical properties, then the functionality and value of the molded object are improved, but the bonding between layers becomes difficult
Solution Approach 1:
The patent applies local quality by creating a mixed material layer where the first and second molding materials are combined in specific regions. This allows different portions of the molded object to have different material compositions - some regions with pure first material, some with pure second material, and some with mixed materials. The mixed material layer is strategically placed at the interface between layers of different materials to provide local bonding enhancement where needed most, while maintaining the overall varying physical properties of the molded object.
Solution Approach 2:
The patent utilizes composite materials by creating a mixed material layer that combines the first molding material and the second molding material. This composite layer serves as an intermediate layer between layers of different materials, leveraging the properties of both materials to achieve compatible bonding. The composite nature of this intermediate layer allows it to bond effectively with both the first material layer and the second material layer, resolving the bonding difficulty between incompatible materials.
2Ease of manufacture
If existing three-dimensional molding techniques are used to laminate different materials, then the manufacturing process is simple, but the ability to create regions within a layer with varying materials is lost
Solution Approach 1:
The patent applies segmentation by dividing each layer into multiple regions with different material compositions. Within a single layer, there are regions containing only the first molding material, regions containing only the second molding material, and regions containing a mixture of both materials. This segmentation is achieved through modified slice data that specifies material distribution at the regional level, allowing complex multi-material structures to be built using standard layer-by-layer lamination processes without requiring fundamentally new manufacturing equipment.
Data Source
AI summary
A molding system to manufacture a three-dimensional object corresponding to a three-dimensional model. The molding apparatus includes a slice data generation unit to generate slice data from three-dimensional shape data of the three-dimensional model, and a lamination unit to laminate a layer of a molding material on the basis of the slice data. The slice data generation unit analyzes data, and, if a region in which a layer of a second molding material different from a first molding material is to be laminated on a layer of the first molding material and in which it is difficult to laminate the layers is extracted, modifies the data of a region of at least one of an ith layer and an (i+1)th layer to data in which a portion in which the first molding material is disposed and a portion in which the second molding material is disposed.