Selective Machining of 3D Printed Surfaces for Roughness Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The selective laser sintering method for manufacturing three-dimensional shaped objects results in a rough surface finish due to powder adherence, necessitating extensive machining that increases manufacturing time and cost, and may cause damage to the object due to machining stress and heat.
Innovation Solution
A method where only the surface portion of the three-dimensional shaped object, which is subjected to force during use, is machined, reducing the need for extensive machining and minimizing damage by focusing machining on specific areas such as cavity-forming surfaces or contact points, and forming high-density portions for improved mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the whole surface of the three-dimensional shaped object is subjected to machining process, then the surface roughness is improved, but the manufacturing time and cost increase significantly
Solution Approach 1:
The patent applies local quality by identifying and machining only the specific surface portions that require improved roughness (such as cavity-forming surfaces or contact surfaces), rather than machining the entire surface. This selective approach maintains the necessary surface quality where needed while avoiding unnecessary machining operations on other surfaces, thereby significantly reducing manufacturing time and cost.
2Manufacturing precision
If the whole surface of the three-dimensional shaped object is subjected to machining process, then the surface roughness is improved, but the manufacturing cost increases
Solution Approach 1:
The patent implements local quality by restricting machining operations to only those surface areas where improved roughness is functionally necessary. This selective machining approach reduces material removal, minimizes machine tool wear, decreases energy consumption, and lowers overall manufacturing costs while still achieving the required surface quality for functional surfaces.
3Manufacturing precision
If extensive machining is performed on the three-dimensional shaped object, then the surface roughness is improved, but the object may suffer damage due to machining stress and heat
Solution Approach 1:
The patent applies local quality by performing machining operations only on specific surface portions that require improved roughness, thereby minimizing the total area subjected to machining stress and heat. This selective approach reduces the cumulative thermal and mechanical loads on the object, preventing potential damage to the laser-sintered microstructure and preserving the overall mechanical strength and reliability of the component.
Solution Approach 2:
The patent employs preliminary action by strategically planning which surfaces require machining before the machining process begins. By pre-identifying the specific surfaces that need treatment (such as cavity-forming surfaces or contact surfaces), the methodology avoids unnecessary machining on other surfaces, thereby preventing exposure to machining-induced stress and heat that could compromise the object's mechanical integrity.
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 significantly reduces manufacturing time and cost while maintaining the mechanical strength of the object by minimizing the machined surface area and preventing unnecessary damage, allowing for efficient production of three-dimensional shaped objects with improved surface roughness.
Implementation Method 1
irradiating a predetermined portion of a powder layer with a light beam, thereby allowing sintering of the predetermined portion of the powder or melting and subsequent solidification thereof
Implementation Method 2
melting and subsequent solidification thereof
Implementation Method 3
The melted powder particles are fused with each other during the subsequent cooling step thereof
Implementation Method 4
a powder layer with a predetermined thickness t1 is firstly formed on a base plate for shaped object 21
Data Source
AI summary
There is provided a method for manufacturing a three-dimensional shaped object. The method of the present invention comprises the repeated steps of: (i) forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing a sintering of the powder in the predetermined portion or a melting and subsequent solidification thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, followed by the irradiation of a predetermined portion of the powder layer with the light beam; wherein only the surface portion of the solidified layer, to which a force is applied when the three-dimensional shaped object is used, is subjected to a machining process.