Conductive Wire Ball Stacking for Precise 3D Metal Shaping
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Solution Overview
Problem
Current methods for producing three-dimensional shaped objects using conductive materials are inefficient due to material waste, high production time, and high costs associated with using expensive powders and specialized equipment like laser devices, which also pose challenges in maintaining shape stability and handling high-temperature materials.
Innovation Solution
A three-dimensional shaped object production device and method that forms balls at the end of a conductive wire using high voltage and aligns them by positioning and bonding, using ultrasonic vibration, pressure, and heat to stack the balls, eliminating the need for expensive powders and specialized equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cutting work or press work is used to produce three-dimensional shaped objects, then the objects can be produced with precise shapes, but large-sized apparatus are required and the operation requires skilled dedicated operators
Solution Approach 1:
The patent replaces traditional mechanical cutting and pressing systems with an electric field-based material deposition system. A conductive wire is melted by electric discharge to form balls that are stacked to create three-dimensional objects, eliminating the need for large cutting tools and skilled operators while maintaining shape precision
Solution Approach 2:
The patent changes the fundamental production parameter from material removal (cutting/pressing) to material deposition (ball stacking). By controlling the melting and stacking process through electric discharge and positioning systems, precise three-dimensional shapes can be built up layer by layer without requiring complex mechanical apparatus
2Manufacturing precision
If material is removed from a material block by cutting work to produce three-dimensional shaped objects, then precise shapes can be obtained, but material waste occurs
Solution Approach 1:
Instead of removing material from a block to create the desired shape, the patent inverts the approach by depositing material (in the form of stacked balls) to build up the three-dimensional object. This additive process eliminates material waste while achieving precise shapes through controlled ball placement
Solution Approach 2:
The patent transitions from a subtractive manufacturing parameter (material removal) to an additive parameter (material deposition). By melting conductive wire to form balls and stacking them according to digital model data, the process achieves precise shapes with minimal material waste
3Productivity
If a laser beam is used to selectively sinter powder to produce three-dimensional parts, then objects can be produced by stacking layers, but expensive powder material and specialized equipment are required
Solution Approach 1:
The patent replaces expensive powder material with a conductive wire that is melted to form balls. The wire serves as a reusable, cost-effective material source compared to disposable powder, eliminating the need for expensive specialized materials while maintaining layer-by-layer production capability
Solution Approach 2:
The patent substitutes the laser sintering system with an electric discharge-based ball formation and stacking system. By using electric field to melt and form balls from conductive wire, the process eliminates the need for expensive laser equipment and specialized powder materials while achieving similar layer-by-layer production
4Stability of the object's composition
If high temperature materials are used to reduce deformation during production, then shape stability improves, but handling becomes difficult
Solution Approach 1:
The patent extracts the high-temperature melting process from the bulk material handling by only melting the wire at the tip to form individual balls. The bulk of the material remains in wire form at room temperature, making it easy to handle and feed through the capillary while the localized melting ensures shape stability during ball formation and stacking
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 reduces material costs, allows for flexible handling of high-temperature materials, and produces objects with reduced weight and deformation, enabling efficient and cost-effective production of complex shapes without the need for expensive devices or high-temperature handling restrictions.
Implementation Method 1
ball forming means for forming a ball at a leading end of a conductive wire, which is inserted into a capillary and is paid out from a leading end of the capillary, by applying high voltage between the leading end of the conductive wire and a spark rod
Implementation Method 2
bonding means for bonding the ball formed at the leading end of the capillary to at least one of the plate or another ball that has already been stacked on the plate, wherein the forming of the ball by the ball forming means, the positioning by the positioning means, and the bonding of the ball formed at the leading end of the capillary by the bonding means are repeated to stack the ball on the plate
Data Source
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AI summary
Provided are a three-dimensional shaped object production device and method capable of producing a predetermined three-dimensional shaped object by forming a ball at a leading end of a conductive wire through use of the conductive wire based on scanned data or designed data and aligning and stacking the balls. The three-dimensional shaped object production device includes: aplate (40), on which a three-dimensional shaped object is placeable; ball forming means for forming a ball (13) by applying high voltage between a leading end of a conductive wire (4) paid out from a leading end of a capillary (12) and a spark rod (19) and melting the leading end of the wire by discharge energy; positioning means for positioning the plate and the ball forming means by moving the plate and the ball forming means relative to each other; and bonding means for bonding the ball formed at the leading end of the capillary to another ball (14) that has already been stacked on the plate, the forming of the ball by the ball forming means, the relative moving of the plate and the ball forming means by the positioning means, and the bonding of the ball formed at the leading end of the capillary to the another ball by the bonding means is repeated, to thereby produce a three-dimensional shaped object having a desired shape.