3D Object Fabrication with Dewetting and Active Cooling
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Solution Overview
Problem
Conventional three-dimensional fabrication techniques require mechanical separation steps, dead zones, or inhibition layers, which are temperature sensitive and limit the build domain, and often result in distorted products due to mechanical cleavage or inefficient cooling.
Innovation Solution
A method and apparatus that utilize a dewetting phase and/or mobile phase to facilitate polymerization without mechanical separation, allowing for omni-directional building and active cooling, eliminating the need for dead zones by using a transparent cooling apparatus and immiscible polymerizable liquids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a dead zone or inhibition layer is used to prevent adhesion at the build interface, then mechanical separation is avoided, but the build domain area is limited and temperature control becomes difficult
Solution Approach 1:
The patent removes the dead zone or inhibition layer from the build interface, extracting the harmful element that limited the build domain. By eliminating this layer, the system achieves continuous polymerization across the entire build area without temperature control issues, while still preventing adhesion through the dewetting phase mechanism.
Solution Approach 2:
The patent introduces a dewetting phase as an intermediary between the build surface and the polymerizable liquid. This intermediary layer prevents adhesion through dewetting forces rather than through inhibition chemistry, allowing the build domain to extend across the entire surface area without temperature-sensitive limitations.
2Temperature
If active cooling mechanisms are used to dissipate heat from the polymerization reaction, then temperature control is improved, but oxygen permeation is inhibited and the dead zone cannot be maintained
Solution Approach 1:
The patent extracts the dead zone concept entirely from the system by using a dewetting phase that prevents adhesion without requiring oxygen inhibition. This allows active cooling mechanisms to be implemented across the entire build domain without compromising oxygen delivery, as the dewetting phase does not rely on chemical inhibition.
Solution Approach 2:
The patent replaces the chemical inhibition mechanism (dead zone) with a physical dewetting mechanism. Instead of using oxygen permeation to prevent adhesion, the system uses surface tension and dewetting forces to achieve the same adhesion prevention effect, thereby enabling effective active cooling without compromising oxygen delivery.
3Ease of manufacture
If mechanical separation steps are used to separate solidified material from the build plate, then layer separation is achieved, but the apparatus becomes more complex and the product may be distorted
Solution Approach 1:
The patent applies preliminary action by pre-coating the build surface with a dewetting phase that creates low adhesion forces before polymerization occurs. This preliminary preparation allows the solidified material to be easily separated from the build plate without requiring complex mechanical separation steps during or after fabrication.
Solution Approach 2:
The patent replaces mechanical separation mechanisms with a chemical/physical dewetting mechanism that prevents adhesion in the first place. By using the dewetting phase to create low surface energy at the build interface, the system eliminates the need for mechanical separation steps, thereby reducing apparatus complexity and avoiding product distortion.
4Area of stationary object
If the polymerization reaction is allowed to proceed continuously without inhibition, then the build domain area is maximized, but heat generation becomes excessive and must be managed
Solution Approach 1:
The patent removes the dead zone that limited polymerization to small areas, allowing continuous polymerization across the entire build domain. The dewetting phase enables this extended polymerization without the temperature control issues that plagued previous systems, as the phase transition mechanism does not rely on oxygen inhibition.
Solution Approach 2:
The patent achieves continuity of useful action by enabling continuous polymerization across the entire build domain without interruption from dead zones or inhibition layers. The dewetting phase allows the polymerization reaction to proceed continuously while managing heat generation through the phase transition mechanism, maximizing both build domain area and productivity.
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
Enables efficient, large-scale, and distortion-free three-dimensional object fabrication with reduced adhesion forces, enabling continuous polymerization and active cooling across the entire build domain.
Implementation Method 1
A three-dimensional object is formed by polymerization of a polymerizable liquid on a dewetting phase
Implementation Method 2
undergoing polymerization of the polymerizable liquid by exposing the build region to energy through at least a portion of the dewetting phase to form a solid polymer
Implementation Method 3
using a mobile phase to provide a shearing interface to reduce interfacial adhesive forces
Data Source
AI summary
Methods and apparatus comprising a dewetting phase and a polymerization liquid that are immiscible, and can be used for the formation of three-dimensional objects, wherein the method does not require a dead zone. Additionally, methods and apparatus that employ an optically transparent cooling apparatus to mitigate heat generated during the fabrication process, and the use of a mobile phase to provide a shearing interface to reduce interfacial adhesive forces.