Multi-dimensional Individualization of Prefabricated Products
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Solution Overview
Problem
Existing methods for individualizing prefabricated products, such as injection molded parts, do not allow for efficient customization or protection against copying, as they lack a systematic approach for applying multi-dimensional information and personalized features.
Innovation Solution
A method involving a device for additive manufacturing that uses a plasticizing unit to apply multi-dimensional individualization by discharging high-pressure drops onto an individualizing surface, allowing for the customization of prefabricated products with features like logos, signatures, or protection against copying, using conventional injection molding materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing is used to apply multi-dimensional individualization to prefabricated products, then customization and protection against copying are enabled, but the process complexity and manufacturing cost increase
Solution Approach 1:
The individualization process is segmented into discrete drops that are applied sequentially to the prefabricated product. Each drop contains specific material and can be positioned precisely, allowing complex multi-dimensional individualization to be built up from simple, manageable units. This segmentation enables customization while keeping each individual drop application simple and controllable.
Solution Approach 2:
The invention transitions from two-dimensional surface marking to three-dimensional multi-dimensional individualization by applying drops that can be shaped, positioned, and oriented in multiple dimensions. This allows logos, signatures, and protective features to be created with depth, texture, and spatial variation, greatly enhancing customization capability beyond traditional surface marking.
2Reliability
If high-pressure drops are discharged onto the individualizing surface, then reliable connection between layers is achieved, but the energy consumption and material requirements increase
Solution Approach 1:
The invention optimizes parameters such as drop size, pressure, and material composition to achieve reliable layer connection with minimal energy consumption. By controlling the pressure within a specific range and adjusting drop dimensions, the system achieves firm bonding without requiring excessive energy input, balancing reliability with energy efficiency.
Solution Approach 2:
The system uses composite material formulations that enhance adhesion and bonding between drops and the substrate. By incorporating specific materials in the drops, reliable connection is achieved more efficiently, reducing the energy required for pressurization and improving overall process efficiency.
3Ease of manufacture
If conventional injection molding materials are used for additive application, then material availability and cost are improved, but the ability to achieve precise multi-dimensional individualization is reduced
Solution Approach 1:
The invention replaces traditional mechanical injection molding processes with a controlled additive deposition system. Instead of using high-pressure injection molds, the system uses precisely controlled drop discharge with digital positioning and shaping, enabling multi-dimensional individualization while maintaining the use of conventional injection molding materials.
Solution Approach 2:
The system applies different material properties and drop characteristics to different locations on the prefabricated product surface. By controlling local conditions such as drop size, material composition, and positioning, precise multi-dimensional individualization is achieved while using the same conventional materials throughout, optimizing both precision and material utilization.
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
Enables the efficient customization of prefabricated products by applying multi-dimensional information, creating unique products from anonymous prefabricated ones, with a reliable and firm connection between layers, and potential protection against counterfeiting.
Implementation Method 1
a plasticizing unit that is known in the injection molding technique and which prepares, mixes and homogenizes the material is coupled to a pressurizable material reservoir
Implementation Method 2
this material is discharged in the form of drops, via a discharge opening. Because of the adhesive forces of the material and the required small drop size, in the range of 0.01 to 0.05 mm3, in this case a pressure at a level of more than 10 to 100 MPa is required
Implementation Method 3
Because of the adhesive forces of the material and the required small drop size
Implementation Method 4
Moreover, the temperature of the material and that of the applied drops can be influenced such that an optimum connection is made between the drop and the substrate
Data Source
AI summary
In a method for the further processing of a product (30) that is preferably prefabricated in large numbers, the product has a surface (31) for an additive multi-dimensional application of material. Information for the additive multi-dimensional application of material is input into a device in which the multi-dimensional application of material is digitised from this information and is deconstructed into elements that are suitable for the additive application of the application of material to the surface (31). The prefabricated product (30) is introduced into a device (I) for additive application of the material application such that the elements for the additive multi-dimensional application of material on the surface (31) are assembled in accordance with the information using an additive manufacturing method. Because the surface is an individualising surface (31) of the prefabricated product, and because the additive application of material is a multi-dimensional individualisation that is intended and suitable for individualising the product, and because at least one of the prefabricated products is identified by the information and is provided individually with the multi-dimensional individualisation (32), a method is provided by which products that are prefabricated in relatively large numbers can be further processed, individualised or personalised to meet individual demands. The prefabricated product (30) is equipped with an associated information carrier for receiving the information for individualisation that supports the method sequence.