3D Printed Multi-Layer Rivet Reinforcement for Interlayer Adhesion
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Solution Overview
Problem
3D-printed multi-layer structures exhibit low interlayer adhesion and are prone to delamination due to anisotropic mechanical properties, with conventional methods facing challenges in efficiently filling gaps between layers.
Innovation Solution
A method involving the distribution of cavities shaped like double-headed rivets across multiple layers during deposition, filled with a filamentary material using a needle-shaped nozzle to form filament-based rivets, enhancing interlayer adhesion without additional post-processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional extrusion methods are used to fill gaps between layers, then the process is simple, but the filament cannot reliably flow into gaps due to high surface tension and limited flow distance
Solution Approach 1:
The gap-filling process is segmented into two phases: (1) a deposition phase where material is extruded through a standard nozzle to form a bridge across the gap, and (2) an infusion phase where a needle-shaped nozzle delivers additional filament directly into the gap from below. This segmentation allows each phase to be optimized independently, overcoming the limitations of single-phase conventional methods.
Solution Approach 2:
A needle-shaped nozzle serves as an intermediary tool that can be positioned precisely within the gap to deliver filament directly to the required location. This intermediary device overcomes the surface tension barrier that prevents conventional extrusion from filling gaps reliably, enabling controlled material delivery deep into the gap structure.
2Reliability
If additional post-processing steps are added to improve interlayer adhesion, then adhesion improves, but manufacturing complexity and time increase
Solution Approach 1:
The gap-filling operation is performed as a preliminary action during the layer deposition process itself, rather than as a subsequent post-processing step. By integrating the needle-shaped nozzle into the existing printing sequence and triggering gap filling immediately after gap formation, the method eliminates the need for separate post-processing operations while ensuring reliable interlayer adhesion.
Solution Approach 2:
The gap-filling function is merged with the layer deposition process by incorporating a needle-shaped nozzle into the multi-nozzle printing system. This integration allows gap filling to occur automatically as part of the normal printing sequence, combining what would traditionally be separate operations (gap creation, material delivery, and bonding) into a unified process that maintains manufacturing efficiency.
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
The method increases interlayer adhesion and reduces the likelihood of delamination by integrating filament-based rivets directly into the 3D printing process, providing a more efficient manufacturing process.
Implementation Method 1
filling the cavity with a second filamentary material in a vertical direction
Implementation Method 2
the second filamentary material cools, contracts, and solidifies after deposition in the cavity
Implementation Method 3
the second filamentary material cools, contracts, and solidifies after deposition in the cavity
Data Source
AI summary
The present disclosure relates to methods and systems for 3D printing. In one example, a 3D multi-layer structure is printed with a cavity distributed over multiple layers of a first filamentary material and shaped as a double-headed rivet. Further, the cavity is filled with a second filamentary material in a vertical direction to form a filament-based rivet, the vertical direction perpendicular to the plane of the multiple layers.