Transparent Unifying Shells for 3D Printed Assembly Positioning
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Solution Overview
Problem
Existing 3D inkjet printing methods struggle to maintain the spatial relative positioning of printed objects and assemblies after support structures are removed, leading to disassembly and loss of original positioning.
Innovation Solution
A method and system for defining a unifying shell that envelops multiple discrete elements, using a bounding box or polyhedron to maintain spatial positioning, and assigning transparent or supporting materials to ensure the elements remain connected during and after printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If support structures are used to sustain specific regions during printing, then the object can be printed successfully with negative angle surfaces and overhangs, but the support structures cause printed objects to disconnect and lose their original spatial relative positioning after removal
Solution Approach 1:
The support construction is segmented into multiple discrete support elements rather than a continuous structure. Each support element is positioned at specific locations to provide necessary support during printing, but is designed to be removable without affecting the relative positioning of printed objects. This segmentation allows support removal without disassembly of the printed assembly.
Solution Approach 2:
A unifying shell is introduced as an intermediary structure that envelops multiple discrete printed elements and support constructions. This unifying shell maintains the spatial relative positioning of all components during and after the printing process, and serves as a protective enclosure that prevents disconnection when support structures are removed.
2Manufacturing precision
If a unifying shell is defined to envelop multiple discrete elements, then spatial relative positioning is maintained, but the device complexity increases due to additional bounding box or polyhedron operations
Solution Approach 1:
The unifying shell serves multiple functions simultaneously: it defines the spatial envelope for maintaining relative positioning, provides a bounding box or polyhedron for computational processing, and acts as a protective enclosure for the printed elements. This multi-functionality reduces the need for separate structures for each purpose.
Solution Approach 2:
The unifying shell is designed as a temporary computational construct that is created during pre-processing to define the spatial envelope, and then its specific geometric form can be simplified or removed in favor of the more robust unifying shell concept that persists through printing. The bounding box or polyhedron operations are performed once during setup rather than continuously.
Data Source
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AI summary
A method of printing a 3D object comprising a plurality of discrete elements, the method comprising: receiving a 3D digital model of a shell group comprising one or more shells representing the plurality of discrete elements; defining, in the 3D digital model, a unifying shell to at least partly envelop one or more shells of the shell group to provide a unified digital model comprising the shell group and the unifying shell; assigning the unifying shell with at least one transparent building material that is transparent upon dispensing and solidifying thereof; assigning the one or more shells of the shell group with one or more building materials; and dispensing, in layers, the at least one transparent building material and the one or more building materials according to the unified digital model to form a 3D object comprising one or more discrete elements that are at least partly connected by a unifying element.