3D Structure Production Using Paste Dispensing and Segmented Forming
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Solution Overview
Problem
Existing methods for producing three-dimensional structures using powder-based techniques are inefficient as they require large amounts of material and often result in unevenness and wastage, limiting the practical application of various compositions.
Innovation Solution
An apparatus and method utilizing a paste-like composition containing grains, where layers are formed and bonded using a dispenser and a binding solution, with a flattening unit to ensure evenness and precision, and an atmosphere control to prevent solvent volatilization, allowing for efficient production of three-dimensional structures with reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a supply table is used to temporarily supply composition to a forming area, then the composition can be supplied to the forming area, but a large amount of composition is wasted because the layer formation area is constant regardless of the three-dimensional structure to be produced
Solution Approach 1:
The patent divides the forming area into multiple independently controllable regions, allowing composition to be supplied only to the specific regions where three-dimensional structures need to be formed. This segmentation enables precise control of material distribution, reducing waste while maintaining productivity across different structure types and sizes.
Solution Approach 2:
The patent implements local quality control by allowing different regions of the forming area to have different properties (formed or unformed). The controller selectively activates only the necessary forming regions based on the specific three-dimensional structure to be produced, ensuring composition is used only where needed rather than uniformly across the entire forming area.
2Manufacturing precision
If powder is thinly spread to form material layers, then layers can be formed, but the process requires large amounts of composition and results in unevenness
Solution Approach 1:
The patent replaces the mechanical spreading method with a direct deposition system where composition is supplied precisely to target locations. This substitution eliminates the unevenness inherent in spreading processes and reduces material consumption by avoiding excess composition that would need to be removed or redistributed.
Solution Approach 2:
The composition is supplied in a paste-like state that maintains its shape and position upon deposition, allowing the material to self-form into uniform layers without requiring additional spreading or leveling operations. This self-service approach ensures layer uniformity while minimizing material waste.
3Area of stationary object
If the entire forming area is used for layer formation, then layers can be formed across the full area, but composition is wasted in areas where three-dimensional structures are not produced
Solution Approach 1:
The patent implements dynamic control of the forming area where regions can be selectively activated or deactivated based on production requirements. The controller dynamically adjusts which portions of the forming area receive composition and undergo layer formation, optimizing both area utilization and material efficiency for different three-dimensional structure production scenarios.
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
The approach enables the efficient production of three-dimensional structures with improved dimensional precision and mechanical strength, while minimizing material usage and preventing unevenness, thus enhancing productivity and reducing costs.
Implementation Method 1
a binder that bonds the grains to each other
Implementation Method 2
adjusts an atmosphere of a space for which the composition is provided, in order to prevent volatilization of a solvent
Data Source
AI summary
An apparatus for producing a three-dimensional structure that produces a three-dimensional structure by laminating layers to each other using a paste-like composition containing grains includes a stage for which the composition is provided and on which the layer is formed; and a dispenser that directly supplies the composition to a forming area on the stage.