Spiral Matrix Structure for Support-Free 3D Ceiling Walls
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Solution Overview
Problem
The challenge is to reduce the weight of three-dimensional shaped objects while maintaining their rigidity and avoiding the need for support materials, especially when shaping ceiling walls, as hollow objects tend to lose rigidity and require additional support structures.
Innovation Solution
A shaping method using a three-dimensional shaping apparatus that stacks spiral constituent layers, where the spiral parts are oriented in a matrix with their major and minor axes orthogonal or parallel to each other, and are turned at predetermined angles to form a structure that connects the bottom and ceiling walls, allowing for efficient shaping without support materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the shaped object is made hollow to reduce weight, then material usage is reduced, but rigidity decreases and support materials are required
Solution Approach 1:
The structure is divided into multiple spiral constituent parts arranged in a matrix pattern, where each spiral part acts as an independent load-bearing element. This segmentation allows the hollow structure to maintain rigidity through the distributed spiral elements rather than requiring solid filling or support materials.
Solution Approach 2:
Spiral forms with curved geometries are used instead of straight linear structures. The curved spiral shape provides inherent structural strength and rigidity while maintaining hollow spaces, eliminating the need for support materials during shaping.
2Strength
If support materials are added to maintain rigidity of hollow objects, then rigidity is maintained, but manufacturing complexity and cost increase
Solution Approach 1:
The spiral constituent parts are designed to self-support during the shaping process. The spiral geometry inherently provides structural stability, allowing the ceiling wall to be shaped without requiring additional support materials or complex manufacturing procedures.
3Strength
If spiral constituent parts are arranged in matrix with orthogonal major and minor axes, then structural rigidity is enhanced, but shaping process complexity increases
Solution Approach 1:
The spiral constituent parts have asymmetric geometries with distinct major and minor axes arranged in orthogonal orientations. This asymmetric arrangement optimizes structural rigidity in multiple directions while the standardized spiral form keeps the shaping process manageable.
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 method enables the creation of lightweight three-dimensional objects with maintained rigidity and facilitates the shaping of ceiling walls without the need for support materials, reducing material usage and production costs.
Implementation Method 1
irradiating the powder layer with a light beam so that the powder layer is sintered or the powder is melted and fixed
Data Source
AI summary
A shaped object shaped by a shaping method includes a structure that is shaped by stacking plural constituent layers and a ceiling wall to support the structure. The structure includes plural spiral form parts. Each spiral form part has a cross section in an elliptic shape and extends in a stacking direction while turning with respect to a center position of the elliptic shape. The plural spiral form parts are disposed in matrix in a state where the center positions are separated from each other by a predetermined distance. The spiral form parts that are adjacently disposed in a row direction and a column direction are shaped so that the turning directions are opposite. In at least one cross section of the structure, the major axes of the spiral form parts that are adjacent in the row direction and the column direction are orthogonal to each other.