Sand-Printed Prototype Models Strengthened by Resin Impregnation
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Solution Overview
Problem
Existing methods for producing prototype models, such as manual prototyping, milling, and 3D printing, face challenges including high time consumption, suboptimal precision, and high costs, particularly in the automotive and aerospace sectors.
Innovation Solution
A method involving sand 3D printing followed by resin impregnation with specific viscosity, density, and pot life characteristics is employed to create prototype models, enhancing strength and detail while reducing production time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual prototyping (clay modeling) is used, then the model can be created with custom design flexibility, but the production time is excessively long and precision is insufficient
Solution Approach 1:
The patent replaces manual mechanical modeling with automated 3D printing technology. The sand 3D printing system uses computer-controlled layer-by-layer deposition to create prototypes, eliminating the need for manual clay modeling while maintaining design flexibility through digital model input.
Solution Approach 2:
The patent changes the fundamental parameter of material state from soft clay requiring manual manipulation to sand particles that are selectively bound by a binder jet. This parameter change enables automated fabrication while preserving design freedom, as the sand can be precisely deposited in any configuration defined by digital models.
2Manufacturing precision
If prototyping by milling is used, then the model can be produced with good surface finish, but the production time is excessively long (2-3 days for a 1-meter automotive model)
Solution Approach 1:
Instead of removing material from a solid block as in milling, the patent uses additive manufacturing where material (sand with binder) is deposited only where needed layer by layer. This inversion of the manufacturing approach dramatically reduces production time while achieving the required surface finish through controlled layer deposition.
Solution Approach 2:
The patent performs preliminary digital preparation of the 3D model, slicing it into layers and generating toolpaths before fabrication begins. This preliminary computational action enables the physical printing process to proceed efficiently without real-time decision-making delays, reducing overall production time while maintaining precision.
3Productivity
If conventional 3D printing methods (SLS, ALS, FDM) are used, then the production time is reduced and precision is improved, but the cost becomes very high due to expensive print materials
Solution Approach 1:
The patent uses sand as the primary material, which is extremely inexpensive compared to the specialized materials required by conventional 3D printing methods. The sand serves as a disposable support structure and final material that can be easily handled and disposed of, dramatically reducing material costs while maintaining production speed and precision.
Solution Approach 2:
The patent changes the material parameter from expensive specialized polymers or metals to common sand particles. This parameter change is enabled by using a binder jetting approach where a binding agent selectively cements sand particles together, allowing the use of low-cost materials while achieving the structural integrity and precision required for high-quality prototypes.
4Productivity
If sand 3D printing is used, then the production time is reduced and cost is lowered, but the structural strength of the model is insufficient
Solution Approach 1:
The patent creates a composite material structure by combining sand particles with a binding agent. The sand provides the structural framework and shape, while the binder cements the particles together to provide structural strength. This composite approach enables the use of weak individual materials (sand) to create a strong final prototype structure.
Solution Approach 2:
The patent changes the physical state and bonding parameters of the sand material. By controlling the binder jet deposition parameters, particle size distribution, and curing conditions, the patent transforms loose sand particles into a structurally sound solid form that can support detailed features and withstand handling, thereby improving strength while maintaining the advantages of sand printing.
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 method achieves faster production times, higher detail precision, and lower costs compared to existing methods, making it suitable for automotive, aerospace, architectural, and artistic applications.
Implementation Method 1
impregnating said sand-printed prototype model with resin
Data Source
Figure 1
Figure 2
AI summary
A method (1) for the production of prototype models, in particular prototypes for the automotive sector, which comprises the steps of: a. creating a prototype model using sand 3D printing; b. impregnating the sand-printed model with resin.