3D Modeling Device Using Pneumatic Material Deposition
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Solution Overview
Problem
Conventional 3D modeling methods face issues such as nozzle damage, material wastage, and warpage due to linear application and large-volume solidification, which affect the quality of the 3D objects produced.
Innovation Solution
A 3D modeling device and method that supply subsidiary and modeling materials in the form of dots, using a low melting point alloy and light-curing resin, respectively, with precise control and separation from the application region, allowing for high-precision application and minimization of material usage, and incorporating a light irradiation unit for curing the resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If modeling material is applied linearly from a nozzle close to the worktable, then the 3D object can be formed, but the nozzle becomes damaged due to contact with the worktable
Solution Approach 1:
The patent introduces a gas medium (air or other gases) as an intermediary between the nozzle and the modeling material. The gas flow carries the modeling material from the nozzle to the application region, eliminating direct contact between the nozzle and worktable while enabling material deposition. This resolves the contradiction by allowing the nozzle to remain positioned away from the worktable surface.
Solution Approach 2:
The patent employs pneumatic principles by using gas flow to transport the modeling material. The gas stream acts as a fluid medium that carries material particles from the nozzle through the air to the target area, enabling contactless material delivery. This pneumatic approach allows the nozzle to maintain safe distance from the worktable while still achieving material application.
2Ease of manufacture
If modeling material is applied linearly from a nozzle, then the 3D object can be formed, but material protrudes from the predetermined region causing waste
Solution Approach 1:
The patent applies local quality by directing the gas flow and material deposition specifically to the predetermined application region. The gas stream is controlled to confine the modeling material within the desired boundaries, preventing protrusion into surrounding areas. This localized material placement eliminates waste while maintaining the ability to form the 3D object.
Solution Approach 2:
The patent changes the delivery mechanism from direct linear contact to gas-mediated transport, altering the material flow parameters. By controlling gas flow rate, direction, and material particle size, the system achieves precise material placement within the predetermined region, preventing wastage while enabling complete 3D object formation.
3Productivity
If large amount of modeling material is applied at the same time, then the 3D object can be formed quickly, but expansion and contraction during solidification cause warpage
Solution Approach 1:
The patent segments the material application process into multiple smaller deposits rather than one large application. The gas flow delivers material in controlled portions, allowing gradual solidification and minimizing thermal expansion and contraction effects. This segmentation approach maintains high productivity while preventing warpage through controlled, incremental material deposition.
Solution Approach 2:
The patent employs periodic action by using pulsed gas flow to deliver modeling material in periodic bursts rather than continuous flow. This periodic delivery allows the material to solidify between pulses, controlling the solidification process and minimizing warpage. The periodic action maintains efficient production speed while ensuring dimensional accuracy through controlled solidification timing.
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 approach enables the creation of high-quality 3D objects by reducing material waste, minimizing warpage, and preventing nozzle damage, while allowing for precise control over material application and curing, resulting in faster production times and improved object quality.
Implementation Method 1
the modeling material is a light-curing resin which is cured by irradiation of light and the 3D modeling device comprises a light irradiating unit arranged lower than the outlet of the modeling material supplying unit and irradiates the modeling material supplied to the region in which the modeling material is to be applied, with light to cure the light-curing resin
Implementation Method 2
the subsidiary material discharged from the outlet of the subsidiary material supplying unit is a low melting point alloy and the 3D modeling device comprises a storing part for storing the low melting point alloy and a heater for heating up the storing part
Data Source
AI summary
A 3D modeling device performs repeatedly a step of cutting a subsidiary material layer formed of a subsidiary material and cutting a modeling material layer formed of a modeling material. The 3D modeling device comprises at least one of a subsidiary material supplying device which discharges the subsidiary material drop by drop from an outlet positioned apart from a region in which the subsidiary material is to be applied at a predetermined distance, and a modeling material supplying device which discharges the modeling material drop by drop from an output positioned apart from a region in which the modeling material is to be applied at a predetermined distance. Since the material can be applied with high precision, a high-quality 3D molded object is provided.