3D Mortar Printing Temperature Control to Prevent Head Blocking

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Solution Overview

Problem

The temperature fluctuations and heat generation during the mixing and pumping of curable binder compositions in 3D printing processes lead to inferior mechanical properties and bonding issues in 3D printed objects, as well as potential blocking of the printing head, due to the high reactivity and viscosity changes of the mortar composition.

Innovation Solution

Implementing real-time temperature measurement and adjustment of the curable binder composition using temperature sensors and heat exchanger devices in the mixing unit, supply line, and printing head to maintain the temperature within target ranges, preventing deviations and ensuring consistent quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If high intensity mixing is used to achieve homogeneous mortar composition, then mixing quality is improved, but temperature increases significantly

Engineering Contradiction:
Improvehomogeneity of mortar compositionVSAvoidtemperature of mortar composition
Core Design Contradiction:
Stability of the object's compositionVSTemperature

Solution Approach 1:

The patent applies preliminary cooling action by introducing cooling elements (such as cooled mixing blades or cooling jackets) into the mixing process before excessive temperature buildup occurs. This prevents the temperature from reaching critical levels while still achieving homogeneous mixing through the preliminary controlled cooling action during the mixing process.

Inventive Principle:
Principle #10Preliminary action

2Speed

If pumping is used to convey mortar composition, then material transport is improved, but temperature increases due to friction

Engineering Contradiction:
Improvematerial transport speedVSAvoidtemperature of mortar composition
Core Design Contradiction:
SpeedVSTemperature

Solution Approach 1:

The patent introduces cooling intermediaries (such as cooled pump components or intermediate cooling chambers) between the pumping action and the mortar composition. These intermediaries absorb the frictional heat generated during pumping, allowing efficient material transport while preventing excessive temperature increase through the intermediary cooling effect.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Speed

If two-component mixing with accelerators is used to speed up curing, then setting speed is improved, but temperature increases due to exothermic reactions

Engineering Contradiction:
Improvesetting speed of mortarVSAvoidtemperature of mortar composition
Core Design Contradiction:
SpeedVSTemperature

Solution Approach 1:

The patent converts the harmful exothermic heat into a beneficial effect by implementing controlled cooling zones that prevent runaway temperature increases. The cooling system is designed to harness the thermal energy from the exothermic reaction and dissipate it in a controlled manner, thereby maintaining the accelerated setting speed while preventing temperature-related defects such as thermal cracking or head blocking.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

4Device complexity

If temperature is not controlled, then process simplicity is maintained, but printing head blocking and weak bonding occur

Engineering Contradiction:
Improvesimplicity of manufacturing processVSAvoidreliability of printing process
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The patent implements self-regulating temperature control mechanisms where the system automatically adjusts cooling based on real-time temperature feedback from sensors. This self-service approach maintains process reliability by preventing blocking and bonding issues without requiring complex external intervention, as the system serves itself through automated thermal management.

Inventive Principle:
Principle #25Self-service

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 ensures the production of high-quality 3D printed objects by preventing temperature-induced issues, such as blocked printing heads and weak layer bonding, thereby improving the safety and efficiency of the additive manufacturing process.

Implementation Method 1

adjusting the temperature of the curable binder composition by cooling, using a heat exchanger device (13.1) arranged to the mixing unit (10)

Methodology Applied
Scientific EffectHeat exchanger: Heat Exchanger

Implementation Method 2

Determining a temperature of the curable binder composition in the mixing unit (10) and/or in the supply line (12) and/or in the printing head (3)

Methodology Applied
Scientific EffectTemperature measurement:

Data Source

PatentEP4458540B1Method and system for producing 3d-object from curable binder composition with additive manufacturing process involving cooling, and relevant computer program
Publication Date: 2025.11.12 SIKA TECH AG
  • EP4458540B1 patent drawingFigure 1

AI summary

A method for producing a three-dimensional object from a curable binder composition with an additive manufacturing process, the method comprises the steps of: - Producing the curable binder composition in the setting state, preferably by mixing the constituents of the curable binder composition in a mixing unit (10), - Conveying the curable binder composition in the setting state via a supply line (12) to a printing head (3) movable in at least one spatial direction, - Applying the curable binder composition in the setting state by means of the printing head (3), wherein the curable binder composition is preferably applied layer-by-layer, to form the three-dimensional object, - Determining a temperature of the curable binder composition in the mixing unit (10) and/or in the supply line (12) and/or in the printing head (3) and/or in the printing head outlet (4), - Adjusting the temperature of the curable binder composition in the mixing unit (10) and/or in the supply line (12) and/or - Adjusting the temperature of at least one of the constituents of the curable binder composition before adding it into the mixing unit (10).