3D Shaping Method with Variable Multilayer Thickness
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Solution Overview
Problem
Conventional three-dimensional shaping methods fail to appropriately set the thickness of each multilayer unit based on the variation in the cross-sectional shape of the object in the horizontal direction, leading to inaccuracies in shaping.
Innovation Solution
A method that divides the object into regions of equal thickness along the z-direction, using Cartesian or rotational coordinates to calculate the variation in cross-sectional shapes, and adjusts the number and thickness of multilayers based on these calculations to ensure accurate shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the thickness of each multilayer unit is set constant, then the manufacturing process is simple, but the shaping accuracy deteriorates when cross-sectional shape varies significantly
Solution Approach 1:
The object model is divided into multiple divided regions along the height direction, with each region having its own optimized multilayer thickness setting. This segmentation allows different thickness values to be applied to different regions based on their cross-sectional shape characteristics, resolving the contradiction between process simplicity and shaping accuracy.
Solution Approach 2:
The multilayer thickness is made dynamic rather than constant, with the thickness varying according to the cross-sectional shape variation in each divided region. This dynamic adjustment enables the system to adapt to different geometric requirements at different heights, improving shaping accuracy while maintaining reasonable process complexity through automated calculation.
2Manufacturing precision
If the thickness of each multilayer unit is decreased to accurately realize the original shape, then the shaping accuracy is improved, but the manufacturing time increases
Solution Approach 1:
Different multilayer thickness values are assigned to different divided regions based on their local cross-sectional shape characteristics. Regions with significant cross-sectional variation receive smaller thickness values for high accuracy, while regions with minimal variation use larger thickness values to reduce manufacturing time. This local optimization resolves the contradiction between accuracy and productivity.
Solution Approach 2:
The multilayer thickness parameter is changed from a constant value to a variable value that depends on the cross-sectional shape variation in each region. By calculating and setting appropriate thickness values for each divided region, the system achieves high shaping accuracy where needed while minimizing the total number of multilayers required, thus reducing manufacturing time.
3Productivity
If the thickness of multilayers is increased to reduce manufacturing time, then the productivity is improved, but the shaping accuracy deteriorates
Solution Approach 1:
The system applies different multilayer thickness values to different divided regions based on their specific cross-sectional shape characteristics. This local quality approach allows the system to use larger thickness values (faster manufacturing) in regions where cross-sectional variation is minimal, while using smaller thickness values (higher accuracy) only where necessary, thus balancing productivity and shaping accuracy.
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 accurate realization of the shaped object by setting the number and thickness of multilayers according to the cross-sectional shape variations, ensuring precise control over the shaping process.
Implementation Method 1
a step of forming a powder layer and a step of sintering the powder layer by application of a moving laser beam or a moving electron beam are alternately repeated
Implementation Method 2
a step of forming a powder layer and a step of sintering the powder layer by application of a moving laser beam or a moving electron beam are alternately repeated
Implementation Method 3
a step of forming a powder layer and a step of sintering the powder layer by application of a moving laser beam or a moving electron beam are alternately repeated
Data Source
Figure 1(a)
Figure 1(b)
Figure 2(a)
AI summary
A three-dimensional shaping method is provided in which a step of forming a powder layer and a step of sintering the powder layer by application of a moving laser beam or a moving electron beam are alternately repeated to perform a multilayer operation within a container, wherein a plurality of equal-width divided regions (2)are set in a multilayer region (4) along a height direction, and then according to certain processes, a number of multilayers N in each of the equal-width divided regions (2) is selected, for selecting a thickness of each multilayer unit in each of the equal-width divided regions (2), and moreover the coordinates of an outer periphery (6) in each of the cross sections (3) of the number N are set.