3D Part Finishing via Liquid Submersion for Surface Roughness Reduction
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Solution Overview
Problem
3D printed parts often exhibit surface roughness and color inconsistencies due to residual unfused build material, which affects their smoothness, glossiness, and color uniformity.
Innovation Solution
Submerging 3D printed parts in a liquid at a temperature above the melting point of the polymeric build material but below the boiling point of the liquid to fuse residual unfused material, resulting in a treated part that is smooth, glossy, and uniformly colored.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If 3D printed parts are produced using additive processes with chemical binders or adhesives, then material application and layer binding are achieved, but surface roughness and color inconsistencies occur due to residual unfused build material
Solution Approach 1:
The patent applies parameter changes by heating the liquid to a temperature above the melting point of the polymeric build material. This temperature parameter change causes the liquid to become viscous and penetrate the porous structure, melting and fusing the residual unfused build material on the part surface, thereby improving surface smoothness and color uniformity
Solution Approach 2:
The patent utilizes phase transitions by heating the liquid to induce melting of the polymeric build material. The liquid transitions from a fluid state to a viscous state, enabling it to penetrate and fuse the residual material. This phase change is critical for achieving the desired surface finish and color consistency
2Manufacturing precision
If liquid is heated to above the melting point of polymeric build material, then surface fusion and smoothing are achieved, but risk of overheating and damaging the part structure increases
Solution Approach 1:
The patent uses a liquid as an intermediary medium to transfer heat to the part surface. The liquid is heated to a temperature above the melting point of the polymeric build material but below its own boiling point, creating a viscous state that allows controlled heat transfer and material fusion without direct contact heating that could cause overheating damage
Solution Approach 2:
The patent carefully controls the temperature parameter within a specific range: above the melting point of the polymeric build material but below the boiling point of the liquid. This parameter optimization ensures sufficient heat for fusion while preventing overheating and structural damage to the part
3Manufacturing precision
If residual unfused build material is melted and fused into the exterior layer, then color uniformity and surface quality improve, but interior material structure may be affected
Solution Approach 1:
The patent applies local quality by targeting only the exterior surface layer of the part for heating and fusion. The liquid penetrates and melts only the residual unfused material on the surface, while the interior material structure remains unaffected. This localized treatment achieves color uniformity without compromising the overall structural integrity
4Manufacturing precision
If traditional machining processes are used to remove material, then surface finish can be improved, but material removal and part complexity increase
Solution Approach 1:
The patent converts the harmful residual unfused build material into a beneficial element by melting and fusing it into the exterior layer. Instead of removing this material through machining, the process uses controlled heating to transform the residual material into a smooth, uniformly colored surface layer, eliminating the need for material removal while achieving superior surface finish
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 treated parts show a significant reduction in surface roughness (up to 10 times) and improvement in gloss (up to 6 times), achieving a uniform color by integrating unfused material into the exterior layer without melting the interior, thus enhancing the aesthetic and surface quality.
Implementation Method 1
submerging a 3D printed part in a liquid that is at a temperature that is above the melting point of a polymeric or polymeric composite build material
Implementation Method 2
submerging the 3D printed part in a liquid that is at a temperature that is above the melting point of a polymeric or polymeric composite build material
Data Source
AI summary
A three-dimensional (3D) part finishing system includes a submerging apparatus to receive a 3D printed part, and a liquid supply container to receive the submerging apparatus. The system further includes a controller operatively connected to the submerging apparatus. The controller is to receive or determine an input time for the 3D printed part and to control submersion of the submerging apparatus into the liquid supply container for the input time.