3D Object Generation with Local Coalescence Control
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Solution Overview
Problem
Additive manufacturing systems face challenges in producing three-dimensional objects with consistent and controllable properties, such as surface roughness, accuracy, and strength, due to variations in build materials and solidification processes, limiting the ability to create objects with variable or uniform properties within a single generated object.
Innovation Solution
The system employs a method of selectively delivering coalescing and coalescence modifier agents to the build material, along with controlled energy application, to modulate the solidification process, allowing for the creation of objects with controllably variable or uniform properties by defining specific patterns and delivery patterns based on object design data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lower cost additive manufacturing systems are used, then production cost is reduced, but object quality and strength deteriorate
Solution Approach 1:
The patent applies local quality by selectively delivering coalescing and coalescence modifier agents to specific portions of build material based on object design data. This enables different regions of the same object to have different properties (e.g., surface roughness, accuracy, strength) by modifying the solidification process locally rather than uniformly across the entire object, allowing high quality in critical areas while maintaining cost-effectiveness.
Solution Approach 2:
The patent changes physical and chemical parameters of the build material by introducing coalescing agents and coalescence modifier agents. These agents alter the solidification behavior, surface characteristics, and mechanical properties of the material during the additive manufacturing process, enabling control over object quality and strength without requiring more expensive equipment.
2Device complexity
If uniform properties are applied throughout the object, then manufacturing process is simplified, but ability to create variable properties in different regions is lost
Solution Approach 1:
The patent enables local quality control by delivering different agents to different portions of build material based on spatial coordinates defined in object design data. This allows the manufacturing process to adapt to regional requirements within the object, creating variable properties (such as different surface roughness or strength in different areas) while maintaining a relatively simple overall manufacturing process through automated agent delivery.
3Strength
If coalescence is increased to improve strength, then inter-layer bonding is enhanced, but surface roughness and accuracy may deteriorate due to coalescence bleed
Solution Approach 1:
The patent introduces coalescence modifier agents as intermediaries that mediate between the coalescing agent and the build material. These modifier agents control the coalescence process by preventing excessive coalescence bleed while maintaining sufficient inter-layer bonding. The modifier agents act as a controlling layer that allows the beneficial effects of coalescence (strength improvement) without the harmful effects (surface roughness and accuracy deterioration).
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 enables the generation of three-dimensional objects with precise control over properties, improving surface roughness, accuracy, and strength by managing coalescence bleed and inter-layer bonding, resulting in objects with desired mechanical and physical characteristics.
Implementation Method 1
a coalescing agent selectively deliverable to a layer of build material provided on a support member
Implementation Method 2
a coalescence modifier agent selectively deliverable to the layer of build material
Implementation Method 3
causing the selective solidification of portions of successive layers of a build material
Data Source
AI summary
According to one aspect there is provided an apparatus for generating a three-dimensional object. The apparatus may include a first agent distributor to selectively deliver a coalescing agent onto portions of a layer of build material, a second agent distributor to selectively deliver a coalescence modifier agent onto portions of the layer of build material, and a controller to control the first and second distributors to selectively deliver each of the agent and the coalescence modifier onto the layer of build material in respective patterns derived from data representing a slice of a three-dimensional object to be generated, in which when energy is applied to the layer of build material, the build material coalesces and solidifies to form a slice of the three-dimensional object in accordance the patterns and the three-dimensional object has mechanical object properties that are related to the patterns.