Solid Personal Care Pattern Cutting for Deep 3D Relief
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Solution Overview
Problem
Existing manufacturing methods for solid personal care products struggle to create elaborate three-dimensional patterns with high accuracy and depth, often resulting in chipped or rounded corners and limited three-dimensional expression due to the use of molds, which can also lead to density differences in the final product.
Innovation Solution
A cutting method using a cutting device with a rotary blade to form a stepped portion with layered stairs, each having a stair width of 0.001 mm to 1 mm, and a height difference of 1 mm or more between the topmost and bottommost portions, allowing for precise three-dimensional patterns without penetrating the base material, thus eliminating the need for molds and ensuring uniform density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mold is used to form three-dimensional patterns on solid personal care products, then the manufacturing process is simple, but the manufacturing precision and three-dimensional expression are limited, resulting in chipped or rounded corners
Solution Approach 1:
The manufacturing process is segmented into two independent stages: (1) forming the solid base material with basic shape, and (2) cutting the three-dimensional pattern on the surface. This segmentation allows the cutting process to achieve high precision without compromising the simplicity of the overall manufacturing process, as the cutting is performed on an already-formed solid surface rather than attempting to form complex three-dimensional shapes directly from mold cavities.
Solution Approach 2:
The solid base material is prepared in advance with a flat surface before the three-dimensional pattern cutting is performed. This preliminary preparation ensures that the cutting process starts with an optimal surface condition, enabling high manufacturing precision for the three-dimensional pattern while maintaining process simplicity through standardized preparation steps.
2Manufacturing precision
If a mold is used to create deep three-dimensional patterns, then the manufacturing process is efficient, but the height difference is limited and corner sharpness is lost
Solution Approach 1:
The process separates base material formation from pattern creation, allowing each stage to be optimized independently. The base material is formed efficiently in one step, then the three-dimensional pattern with sharp corners and precise details is cut with high precision, achieving both manufacturing efficiency and pattern quality without compromise.
Solution Approach 2:
The traditional mold-based mechanical forming system is replaced with a cutting system that uses a blade to remove material. This substitution enables the creation of sharp corners and precise three-dimensional patterns that cannot be achieved with mold pressing, while maintaining manufacturing efficiency through automated cutting processes.
3Stability of the object's composition
If mold pressing is used to form three-dimensional patterns, then the process is simple and fast, but density differences occur in the final product
Solution Approach 1:
The process is divided into independent stages where the solid base material is first formed with uniform density through controlled solidification, then the three-dimensional pattern is cut on the surface. This segmentation prevents the density issues caused by mold pressing, as the cutting process removes material rather than compressing it, maintaining uniform density throughout the product while preserving process simplicity through standardized steps.
4Manufacturing precision
If the cutting depth is increased to create deeper three-dimensional patterns, then the three-dimensional effect is enhanced, but the risk of penetrating the base material increases
Solution Approach 1:
The cutting process incorporates feedback control where the cutting depth is precisely monitored and regulated to ensure it does not exceed the safe limit of penetrating the base material. This feedback mechanism allows the creation of deep three-dimensional patterns with enhanced visual effect while maintaining the integrity and reliability of the base material structure.
Solution Approach 2:
The base material is prepared with sufficient thickness and structural integrity before the cutting process begins. This preliminary preparation ensures that even when deep cuts are made to enhance the three-dimensional effect, the base material maintains its integrity and does not penetrate through, as the cutting parameters are predetermined based on the base material properties.
Data Source
AI summary
A manufacturing method for a solid personal care product having a three-dimensional pattern comprises a cutting process of cutting a solid base material provided on a target object such that the base material is not penetrated. In the cutting process, the base material can be cut such that a stepped portion can be formed, where the stepped portion can include a plurality of layered stairs each having a stair width in a height direction of 0.001 mm or more and 1 mm or less, and a difference in height between a topmost portion and a bottommost portion of a surface of the base material can be 1 mm or more.