Selectable-Material Manufacturing Device for Additive/Subtractive Modes
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Solution Overview
Problem
Existing multi-technique manufacturing devices are costly and complex due to separate additive and subtractive systems stitched together, lacking efficiency and versatility in material processing.
Innovation Solution
A single manufacturing device with a configurable light source and modular trays/vats for additive and subtractive processes, enabling seamless switching between additive manufacturing modes using powder or resin, and engraving/cutting operations without hardware changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate additive and subtractive manufacturing systems are stitched together to create multi-technique devices, then multiple manufacturing capabilities are achieved, but device complexity and cost increase significantly
Solution Approach 1:
The patent combines additive manufacturing (SLA and SLS) and subtractive manufacturing (ECM) capabilities into a single integrated device. The same light source, control system, and structural components serve multiple manufacturing functions, eliminating the need for separate stitched systems and reducing overall device complexity while maintaining versatility
Solution Approach 2:
The device employs universal components that perform multiple functions: the light source enables both SLA and SLS additive processes, the same apparatus supports ECM subtractive manufacturing, and the tray/vat structure adapts to accommodate different materials and processes, allowing one device to replace multiple specialized machines
2Adaptability or versatility
If separate additive and subtractive manufacturing systems are stitched together, then multiple manufacturing techniques are supported, but manufacturing efficiency and productivity decrease
Solution Approach 1:
By merging additive and subtractive manufacturing processes into a single device with unified control and material handling, the system eliminates the inefficiencies of transferring workpieces between separate machines, reduces setup time, and enables seamless multi-technique manufacturing workflows that improve overall productivity
Solution Approach 2:
The device allows for preliminary configuration of trays, vats, and process parameters before manufacturing begins. The system can pre-load different materials (resin, powder, metal, wood, plastic) and pre-configure the light source and control parameters for the specific manufacturing technique to be used, reducing setup time and improving manufacturing efficiency
3Manufacturing precision
If multiple specialized manufacturing devices are used, then each process is optimized, but material processing versatility is limited
Solution Approach 1:
The device is designed with universal material handling capabilities that support diverse materials including resins, powders, metals, wood, and plastics. The same light source and structural components can process different material types through appropriate parameter adjustments and tray/vat configurations, expanding material processing versatility while maintaining process optimization for each material type
Solution Approach 2:
The system optimizes manufacturing precision for different materials and processes by dynamically adjusting parameters such as light source power, wavelength, exposure time, and tray/vat configuration. The control system can modify these parameters based on the detected material type and desired manufacturing process, maintaining high precision across diverse material processing applications
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
Enhances productivity and reduces costs by integrating multiple manufacturing techniques in a single apparatus, supporting a wide range of materials and processes with improved efficiency and versatility.
Implementation Method 1
The emitted beam is directed to a transparent window at the bottom of the SLS tray, through which the beam can focus on a spot on the powder side of the transparent window to fuse the powder that resides at that location
Implementation Method 2
The same apparatus can also be configured to fabricate a three-dimensional object using a powder by using a tray that is designed for selective laser sintering (SLS)
Implementation Method 3
The same apparatus can also be configured to fabricate a three-dimensional object using a photo-curable resin
Data Source
AI summary
A novel approach to digital manufacturing is disclosed. In one embodiment, a single light source is provided in a single digital manufacturing device that can be configured to fabricate a three-dimensional object from liquid resin materials or configured to fabricate a three-dimensional object from powder or the same device can be configured to etch, cut, or mark a workpiece. The changes in configuration can occur through swapping out the hardware for containing the build material and/or by switching configuration using a computer or a physical switch.