3D Shaping Angle Optimization for Undercut Deformation
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Solution Overview
Problem
Three-dimensional shaped products with undercut regions often deform during sintering due to their weight, and existing methods rely heavily on support sections, which can alter the product's design and hinder shaping.
Innovation Solution
A method involving lamination, sintering with laser or electron beam irradiation, and cutting, controlled by a CAD/CAM system, where shaping angles are optimized to minimize or eliminate the need for support sections by calculating and adjusting rotation angles along the XZ and YZ planes to prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If support sections are added to prevent deformation of undercut regions, then deformation is suppressed, but the product design is altered and shaping is hindered
Solution Approach 1:
The invention changes the shaping angle parameter of the undercut region to be within a specific range (30° to 60° from the horizontal direction). By adjusting this geometric parameter, the structure achieves sufficient stability during sintering without requiring additional support sections, thus preventing deformation while maintaining design integrity and shaping ease.
2Quantity of substance
If the area of horizontal plane above undercut region is large, then more material is used, but deformation accidents occur more easily
Solution Approach 1:
By controlling the shaping angle within the specified range, the invention optimizes the structural distribution of the horizontal plane area. This parameter change ensures that even when large horizontal areas are present, the undercut regions maintain adequate support and stability during sintering, preventing deformation without reducing the necessary material quantity for functional requirements.
3Ease of manufacture
If shaping angles are optimized to eliminate support sections, then design integrity is maintained, but deformation prevention becomes more difficult
Solution Approach 1:
The invention establishes a specific parameter range for shaping angles (30° to 60° from the horizontal direction) that simultaneously achieves both design integrity and deformation prevention. Within this optimized parameter range, the structure inherently maintains stability during sintering without requiring support sections, thus preserving design integrity while ensuring reliable deformation prevention.
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 prevents deformation and reduces the necessity for extensive support sections, enabling more efficient and stable shaping of three-dimensional products with undercut regions.
Implementation Method 1
sintering with irradiation of a laser beam or electron beam
Implementation Method 2
sintering with irradiation of a laser beam or electron beam
Implementation Method 3
sintering with irradiation of a laser beam or electron beam
Data Source
AI summary
A method for a three-dimensional shaped product produced by lamination, irradiation-based sintering and cutting, when undercut regions are present, comprising the steps of:1. setting a model for the three-dimensional shaped product;2. selecting a standard of undercut angle;3. rotating the model in angle units;4. calculating a total projected area on a horizontal plane of the undercut regions having angles crossing the horizontal plane which are smaller angles than a standard of undercut angle;5. selecting a rotation angle such that the total projected area is either smallest or a prescribed standard value is reached;6. when a minimum total area in step 5 is larger than a predetermined standard value or all of the total projected area in step 4 is larger than the predetermined standard value, sending a command to set a shaping region of a support section for supporting the undercut region.