3D Laser Conformal Flexible Sensors Without Transfer Printing
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Solution Overview
Problem
Current manufacturing techniques for flexible sensors on 3D curved surfaces are inefficient, lack precision, and have limited adaptability due to the need for cumbersome and time-consuming processes like transfer printing, which often result in decreased sensor performance.
Innovation Solution
A laser conformal manufacturing method using a 3D dynamic focus system to directly process nanomaterials and composite materials on 3D curved surfaces, involving scanning, STL model construction, clamper creation, material coating, and laser processing to achieve a perfectly conformal flexible sensor attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If transfer printing technology is used to attach flexible sensors to 3D curved surfaces, then the sensors can be attached to curved surfaces, but the process becomes cumbersome and time-consuming with decreased precision
Solution Approach 1:
The patent replaces the mechanical transfer printing process with a direct laser-based manufacturing approach. The laser system directly writes and patterns materials on the 3D curved surface without requiring mechanical transfer, splicing, or attachment operations, thereby eliminating the time-consuming mechanical processes while maintaining adaptability to complex geometries
Solution Approach 2:
The patent transitions from 2D planar manufacturing to 3D conformal manufacturing by using laser technology that can operate on curved surfaces. The laser system adapts its focal plane and scanning path to match the 3D geometry, enabling direct manufacturing on curved surfaces without the need to flatten, transfer, or splice 2D components
2Adaptability or versatility
If transfer printing technology is used to attach flexible sensors to 3D curved surfaces, then the sensors can be attached to curved surfaces, but the process becomes cumbersome and complex
Solution Approach 1:
The patent replaces the complex mechanical transfer printing system with a simpler laser-based direct writing system. The laser system requires only optical components and software control, eliminating the need for mechanical transfer stages, splicing mechanisms, and complex alignment systems, thereby reducing overall process complexity
Solution Approach 2:
The patent merges multiple separate operations (material deposition, patterning, and shaping) into a single laser processing step. The laser system performs all these functions simultaneously through controlled scanning and focal adjustment, eliminating the need for separate transfer printing, splicing, and attachment operations
3Adaptability or versatility
If transfer printing technology is used to attach flexible sensors to 3D curved surfaces, then the sensors can be attached to curved surfaces, but the precision of the flexible sensor decreases
Solution Approach 1:
The patent replaces mechanical transfer and splicing operations with direct laser writing, which inherently provides higher precision. The laser system can directly pattern materials with micrometer-scale accuracy on the curved surface without the precision losses associated with mechanical transfer, alignment, and splicing operations
Solution Approach 2:
The patent enables direct 3D conformal manufacturing that maintains precision by adapting the laser focal plane to the curved surface geometry. This eliminates the precision degradation that occurs when 2D patterns are transferred and spliced onto 3D surfaces, as the manufacturing process operates natively in 3D space
4Ease of manufacture
If conventional manufacturing techniques are used on 2D plane substrates, then manufacturing processes are well-established, but they cannot be directly used for conformal manufacturing on 3D curved surfaces
Solution Approach 1:
The patent extends conventional 2D manufacturing techniques to 3D curved surfaces by using laser technology that can operate in three-dimensional space. The laser system adjusts its focal plane and scanning path to conform to the curved surface geometry, enabling direct manufacturing on 3D objects without requiring flat substrates or complex transfer processes
Solution Approach 2:
The patent replaces mechanical 2D substrate-based manufacturing with a laser-based direct writing system that operates independently of substrate geometry. The laser system uses optical focusing and scanning control to achieve conformal manufacturing on curved surfaces, eliminating the constraint of requiring flat 2D substrates
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 method significantly improves processing efficiency and precision, allowing for precise attachment of flexible sensors to complex 3D surfaces without the need for secondary splicing or transfer printing, enhancing the adaptability and performance of the sensors.
Implementation Method 1
laser processing to achieve a perfectly conformal flexible sensor attachment
Implementation Method 2
laser processing to achieve a perfectly conformal flexible sensor attachment
Implementation Method 3
laser conformal manufacturing method using a 3D dynamic focus system
Data Source
AI summary
A laser conformal manufacturing method of a flexible sensor comprises: obtaining morphology data of a curved surface, and constructing a Standard Triangle Language (STL) model of the curved surface; introducing into a 3D modeling software, and combining the curved surface with a clamper holder; manufacturing to obtain the clamper with the curved surface; coating material to be manufactured on a 3D curved surface of the clamper with the curved surface; positioning to a processing platform of a laser device; constructing a model of a pattern to be manufactured by laser based on the STL model of the curved surface, and constructing an STL model or a dwg model of the pattern to be manufactured; introducing into the laser device, turning on the laser device, and running a 3D dynamic focus system; repeating the steps 4-8, and stripping the flexible sensor from the 3D curved surface.