Spiral Sheet Additive Manufacturing Bypassing Build Chamber Limits
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Solution Overview
Problem
Current 3D printers have limitations on the maximum volume of their build chambers, making it impossible to manufacture large parts, especially those exceeding the build chamber dimensions, which are needed for commercial applications in various industries.
Innovation Solution
A method of manufacturing a spiral sheet product via additive manufacturing, where the geometry of the product includes a spiral body with repeating sections and unit cells, each containing a geometric pattern. This allows the product to be arranged into a flat sheet that is larger than the build chamber of the 3D printer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the build chamber volume of 3D printers is increased to manufacture large parts, then the maximum part size that can be manufactured increases, but the cost and complexity of the equipment increases significantly
Solution Approach 1:
The patent divides a large part into multiple smaller sections that can be manufactured separately within the existing build chamber constraints. These sections are then assembled together to form the complete large part, effectively bypassing the need for a larger build chamber while maintaining the ability to produce large-scale components
Solution Approach 2:
The patent introduces a spiral configuration that transforms the manufacturing problem from a 2D plane expansion issue to a 3D volumetric utilization problem. By winding the sheet in a spiral pattern around a central axis, the system achieves large flat sheet dimensions through vertical stacking and rotational arrangement rather than horizontal expansion, effectively utilizing the build chamber's vertical space
2Length of stationary object
If large parts are sectioned into smaller portions and assembled, then parts larger than build chamber can be manufactured, but the structural integrity and consistency of the final product deteriorates
Solution Approach 1:
The patent merges multiple smaller printed sections into a single continuous spiral structure where the sections are interconnected through shared walls and common support structures. This integration ensures that load paths continue across section boundaries, maintaining structural integrity while enabling the manufacture of large parts that exceed build chamber dimensions
Solution Approach 2:
The patent employs a nested structure where multiple spiral sections are arranged concentrically around a central axis, with each section nesting within the spatial envelope of the previous section. This nested arrangement allows sections to share common support structures and connection points, ensuring structural continuity and integrity across the entire assembled part
3Length of stationary object
If multiple smaller portions are printed separately and assembled, then large parts can be manufactured, but the manufacturing time increases due to additional assembly steps
Solution Approach 1:
The patent incorporates preliminary action by designing self-aligning features and integrated connection structures that are built into each section during the printing process. These pre-configured alignment features eliminate the need for complex post-printing alignment and assembly operations, significantly reducing the time required to combine multiple printed sections into the final large part
Data Source
AI summary
The present disclosure generally relates to a method of manufacturing a spiral sheet product via an additive manufacturing process, the method comprising: obtaining an electronic file representing a geometry of the spiral sheet product; and controlling an additive manufacturing apparatus to manufacture, via the additive manufacturing process, the spiral sheet product according to the geometry specified in the electronic file. The geometry of the spiral sheet product comprises: a geometric model of a spiral body revolving around a longitudinal axis, the spiral body comprising spiral sections repeating along the longitudinal axis; each spiral section comprising unit cells repeating along a spiral length of the spiral section; and each unit cell comprising a geometric pattern, such that the repetitive geometric pattern functionalizes the spiral sheet product that is arrangeable into a flat sheet product that is larger than a build chamber of the additive manufacturing apparatus.