Transparent Matrix Encasing for Complete 3D Printed Models
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Solution Overview
Problem
Existing 3D printing technologies, such as selective laser sintering and stereolithography, require powerful lasers and large volumes of matrix material, making them impractical for domestic use, and conventional methods for generating 3D models from virtual environments often result in incomplete or distorted printed objects due to limited viewpoint rendering.
Innovation Solution
A method using fused deposition modeling (FDM) with an entertainment device, such as the PlayStation 4, captures multiple rendered images from different viewpoints and employs virtual photogrammetry techniques to generate a voxel model, ensuring comprehensive coverage and integrity of the 3D printed object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If selective laser sintering or stereolithography is used to create 3D models, then manufacturing precision and model integrity are improved, but device complexity and cost increase due to requiring powerful lasers and large volumes of matrix material
Solution Approach 1:
The patent extracts the model creation process from the complex laser-based systems and separates it into a simpler FDM-based approach. The FDM printer creates the model without requiring powerful lasers or large volumes of matrix material, thereby reducing device complexity while maintaining model integrity through the subsequent encapsulation step.
Solution Approach 2:
The patent introduces an intermediary transparent material that encapsulates the FDM-created model. This intermediary material serves multiple functions: it protects the model, provides structural support, and enables the model to be created with simpler equipment while maintaining the integrity that would otherwise require complex laser-based systems.
2Productivity
If conventional 3D modeling from virtual environments is used, then productivity is improved, but manufacturing precision deteriorates due to incomplete coverage and distortion from limited viewpoint rendering
Solution Approach 1:
The patent segments the modeling process into multiple viewpoint captures, treating each viewpoint as a separate data source. By capturing images from multiple angles and positions, the system overcomes the limitation of single-viewpoint rendering, ensuring complete coverage and accurate representation of the virtual environment without sacrificing productivity.
Solution Approach 2:
The patent transitions from two-dimensional single-viewpoint rendering to multi-dimensional multi-viewpoint capture. By adding the dimension of multiple camera positions and angles, the system achieves complete spherical coverage of the virtual environment, eliminating distortion and ensuring manufacturing precision while maintaining efficient automated modeling.
3Ease of manufacture
If FDM technology is used for 3D printing, then ease of manufacture and accessibility are improved, but manufacturing precision may be compromised compared to laser-based methods
Solution Approach 1:
The patent merges FDM printing with transparent material encapsulation in a single integrated process. The FDM printer deposits material layer by layer to create the model, while simultaneously or subsequently depositing transparent material to encapsulate it. This combination allows domestic FDM printers to produce high-fidelity models that would otherwise require complex laser-based systems.
Solution Approach 2:
The patent uses composite material deposition, combining the model material ( deposited by FDM) with transparent encapsulation material. This composite approach allows the model to be created with accessible FDM technology while the transparent material provides the structural integrity and precision that would otherwise require powerful lasers and specialized equipment.
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 allows for the creation of high-fidelity, complete, and accurate 3D printed models from virtual environments, suitable for domestic use, by leveraging the capabilities of FDM technology and advanced image processing to overcome limitations of previous methods.
Implementation Method 1
A method using fused deposition modeling (FDM) with an entertainment device
Data Source
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AI summary
A method of 3D print modelling comprises the steps of obtaining a target virtual object for 3D printing, evaluating the target virtual object for 3D printing with respect to one or more printability criteria to detect whether the 3D printed model would have one or more predetermined undesirable physical characteristics, and if so, generating 3D printable model data defining a transparent matrix to be printed surrounding the 3D printed model of the target virtual object.