3D Shaping Method Using Partial Squeegee Travel
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Solution Overview
Problem
Existing shaping methods for three-dimensional products result in excess powder layers and inefficient squeegee movement, with powder falling from gaps between the chamber wall sections and the shaping table, due to the formation of powder layers over the entire region on the shaping table.
Innovation Solution
A shaping method where the squeegee travels a shorter distance than the full distance between chamber wall sections, forming powder layers only over a partial region on the shaping table, with specific locations of wall layers established to prevent collapse and excess powder formation, and sintered layers formed by laser or electron beam irradiation, adjusting the powder amount to maintain layer integrity and minimize outer powder formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If powder layers are formed over the entire region on the shaping table corresponding to the full traveling distance of the squeegee, then the powder layers can be connected with the wall sections to maintain structural stability, but excess powder layers are formed and working efficiency deteriorates
Solution Approach 1:
The patent applies local quality by forming powder layers only in the necessary partial region on the shaping table rather than the entire region. The squeegee travels distance L which is shorter than the full chamber width, creating powder layers only where needed for the three-dimensional shaped product. This localized approach maintains structural stability through proper wall section connections while eliminating excess powder layer formation, thereby improving working efficiency.
2Productivity
If powder layers are formed over a partial region on the shaping table to improve working efficiency, then excess powder formation is reduced, but the powder layers cannot maintain their form and collapse occurs
Solution Approach 1:
The patent applies preliminary action by establishing the traveling distance L of the squeegee in advance before forming the powder layers. This predetermined distance is specifically set to ensure that powder layers are formed only in the region necessary to connect with wall sections while maintaining form stability. By pre-establishing this optimal traveling distance, the system prevents both excess powder formation and layer collapse, achieving both improved productivity and maintained structural integrity.
3Productivity
If the traveling distance of the squeegee is shortened to reduce excess powder formation, then working efficiency is improved, but powder layers may collapse due to insufficient connection with wall sections
Solution Approach 1:
The patent applies parameter changes by optimizing the traveling distance L of the squeegee as a critical parameter. This distance is specifically adjusted to be shorter than the full chamber width but sufficient to ensure proper connection with wall sections. By precisely controlling this parameter, the system achieves the optimal balance between improving working efficiency (reducing excess powder) and maintaining reliability (preventing layer collapse through adequate wall section connection).
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 prevents powder layer collapse and excess powder formation, improving squeegee efficiency and reducing powder loss from gaps, ensuring efficient powder use and effective lamination of three-dimensional shaped products.
Implementation Method 1
sintering of a shaping region by irradiation with a laser beam or an electron beam
Implementation Method 2
sintering of a shaping region by irradiation with a laser beam or an electron beam
Implementation Method 3
formation of powder layers by movement of a squeegee
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3(a)
AI summary
Disclosed is a shaping method for a three-dimensional shaped product, which employs following processes after formation of powder layers on the top side of a shaping table 1 and sintering by a beam: 1. Setting a traveling distance of the squeegee to be a short distance that does not reach a chamber wall section. 2. Establishing location of wall layers connecting both ends at the chamber wall sections in a direction perpendicular to the traveling direction of the squeegee, within a traveling range based on the traveling distance set by the process 1, or connecting to the ends on a powder feeder side at inner side of the chamber wall sections with a state surrounding a region that is to be sintered, from both sides of the region. 3. Forming powder layers by movement of the squeegee over the traveling distance set in the process 1. 4. Forming sintered layers by irradiation with a beam on the powder layers formed by the process 3, and forming wall layers by irradiation with a beam at the locations of the wall layers established by the process 2. 5. Repeating the processes 3 and 4.