3D Inkjet Printing Sequence to Reduce Material Mix Layers
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Solution Overview
Problem
3D inkjet printing methods often result in a matte appearance and surface inconsistencies due to mixing of uncured modeling and support materials, which negatively impact the surface appearance and mechanical properties of the final 3D object.
Innovation Solution
A 3D inkjet printing system that separates the deposition and curing of modeling and support materials either in time or space, controlled within a predefined oxygen concentration range of 1% to 10% and temperature range of 15°C to 35°C, reducing the thickness of the mix layer at their interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If modeling material and support material are deposited simultaneously in liquid state, then printing efficiency is improved, but surface quality deteriorates due to mix layer formation
Solution Approach 1:
The patent segments the deposition process into distinct temporal phases: support material is deposited and cured first, then modeling material is deposited afterward. This temporal segmentation prevents simultaneous contact of liquid materials, eliminating mix layer formation while maintaining efficient printing through automated sequential processing
Solution Approach 2:
The support material is deposited and cured in advance before the modeling material is applied. This preliminary action creates a stable, non-liquid substrate that prevents mixing with subsequent modeling material deposition, ensuring high surface quality from the outset
2Device complexity
If oxygen concentration is not controlled during curing, then process simplicity is maintained, but surface smoothness deteriorates due to mix layer
Solution Approach 1:
The patent implements an inert atmosphere environment with controlled oxygen concentration (1-10%) during the curing process. This inert environment prevents oxygen inhibition of polymerization at the material interface, eliminating the cause of mix layer formation and surface roughness while maintaining process simplicity through automated atmospheric control
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 results in significantly glossier external surfaces and improved mechanical properties of the 3D objects by minimizing the thickness of the mix layer, enhancing surface smoothness and strength.
Implementation Method 1
controlling a temperature in the printing chamber to be in a predefined temperature range of 15°C to 35°C or 20°C to 30°C by injection of a cooled inert gas at a temperature of 1°C to 20°C
Implementation Method 2
a curing subunit configured to provide controllable environmental conditions during the printing of the 3D object
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A method of printing a three-dimensional object (90) including: providing a 3D inkjet printing system including: a printing chamber (162) accommodating a printing unit (120) having an inkjet printing head and a curing subunit (124), and a supply unit (130) including a modeling material and a support material; and printing the 3D object (90) in multiple consecutive layers according to a predefined printing sequence, wherein for at least one of the multiple consecutive layers the predefined printing sequence for the same respective layer includes depositing and curing the modeling material and the support material separately from each other either in time or in space. Some embodiments may include controlling a concentration of oxygen in the printing chamber (162) to be in a predefined oxygen concentration range. Some embodiments may include controlling a temperature in the printing chamber (162) to be in a predefined temperature range.