3D Printed Part With Voxel-Level Ductility Tailoring
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Solution Overview
Problem
Existing 3D printing methods struggle to create parts with varying mechanical properties or gradient mechanical properties without modifying the build material, limiting the ability to form parts with specific desired mechanical properties in different areas.
Innovation Solution
A ductility tailoring agent, comprising a miscible solid that is partially soluble in a water-based solvent system and compatible with amide or amine functionalities of the build material, is selectively jetted during the printing process to impart controlled ductility at the voxel level, allowing for the formation of parts with varying mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional 3D printing methods are used without modifying build material, then the printing process is simple, but the ability to create parts with varying mechanical properties in different areas is limited
Solution Approach 1:
The patent applies local quality by selectively applying a ductility tailoring agent to specific regions of the build material layer. This allows different areas of the printed part to have different mechanical properties (ductile vs. non-ductile) based on where the agent is applied, enabling spatial variation of material properties without changing the overall printing process complexity
Solution Approach 2:
The ductility tailoring agent acts as an intermediary substance that modifies the mechanical properties of the build material locally. This agent serves as a mediator between the printing process and the final mechanical properties, allowing control over ductility without requiring fundamental changes to the 3D printing system itself
2Strength
If build material is modified to achieve desired mechanical properties, then mechanical strength is improved, but the build material cannot easily provide different mechanical properties in different areas
Solution Approach 1:
Instead of uniformly modifying the build material, the patent uses local quality by selectively applying the ductility tailoring agent to specific regions. This enables the same build material to produce areas with different mechanical properties (ductile where agent is applied, non-ductile where it is not), achieving spatial variation without sacrificing mechanical strength
Solution Approach 2:
The patent changes the physical-chemical parameters of the build material locally by introducing the ductility tailoring agent. This agent alters the mechanical properties (ductility, elongation at break) in specific regions through parameter changes rather than requiring different build materials for different areas
3Manufacturing precision
If ductility tailoring agent is selectively applied to build material layer, then controlled ductility is achieved at voxel level, but the process complexity increases
Solution Approach 1:
The patent achieves manufacturing precision by controlling the application parameters of the ductility tailoring agent (amount, location, timing). This allows voxel-level control of ductility through precise parameter management rather than requiring complex hardware modifications, maintaining process simplicity while achieving high precision
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 enables the creation of 3D printed parts with enhanced ductility, flexibility, and mechanical strength, achieving up to 10 times higher elongation at break and toughness compared to traditional methods, while maintaining mechanical stability and preventing miscible solid migration.
Implementation Method 1
The fusing agent is capable of absorbing radiation and converting the absorbed radiation to thermal energy, which in turn melts or sinters the build material that is in contact with the fusing agent
Implementation Method 2
The ductility tailoring agent includes a miscible solid that is at least partially soluble in a water-based solvent system and that is compatible with the amide functionality of the build material
Implementation Method 3
for some materials, at least partial melting may be accomplished using heat-assisted extrusion, and for some other materials (e.g., polymerizable materials), curing or fusing may be accomplished using, for example, ultra-violet light or infrared light
Data Source
AI summary
In an example, a three-dimensional (3D) printed part comprises a plurality of fused build material layers including exterior layers and interior layers. At least some of the interior layers include a composite portion having a miscible solid physically bonded to an amide functionality or an amine functionality of the build material. The miscible solid is a solid at a room temperature ranging from about 18° C. to about 25° C.