3D Printed Part Surface Remelting for Bioprocessing Finish
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Solution Overview
Problem
Existing 3D printed objects have rough surfaces and thus need some form of post-processing to achieve the required surface finish to achieve the required surface finish, but this method.
Innovation Solution
Existing methods for improving the surface finish of 3D printed parts are joining parts or intended for use with wetted components such as chromatography columns, filtration units, and tubing in a bioprocessing system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If post-processing methods such as tumbling, sanding, or bead blasting are applied to improve surface finish, then surface quality improves, but device complexity and processing time increase
Solution Approach 1:
The patent replaces mechanical post-processing methods (tumbling, sanding, bead blasting) with a thermal field approach. A heating element applies controlled heat to melt the rough 3D printed surface, and a roller with a polished surface applies pressure to smooth the molten material, transferring the roller's smooth surface finish to the part. This substitution of mechanical removal processes with thermal-mechanical forming resolves the contradiction by achieving superior surface finish without complex multi-step mechanical post-processing equipment.
Solution Approach 2:
The patent changes the physical state of the 3D printed material by heating it above its melting point, transforming the solid rough surface into a molten state that can be easily reshaped. By controlling temperature parameters (heating to melt, then cooling to solidify), the rough as-built surface is converted into a smooth finished surface. This parameter change approach eliminates the need for multiple mechanical processing steps, reducing device complexity while improving surface finish.
2Manufacturing precision
If ironing or hot gunning is used to improve surface finish, then surface quality improves, but processing time increases and safety concerns arise
Solution Approach 1:
The patent replaces the time-consuming ironing process (which requires depositing and melting additional thermoplastic layers) with a direct heating and rolling approach. Instead of adding material and re-melting it, the system directly heats the existing rough surface and uses a polished roller to smooth it during cooling. This eliminates the additional material deposition and re-melting steps, significantly reducing processing time while maintaining improved surface finish.
Solution Approach 2:
The patent introduces a roller as an intermediary tool between the heating element and the 3D printed part. The roller serves multiple functions: it applies pressure to the molten surface, transfers the smooth finish from its polished surface to the part, and facilitates controlled cooling. This intermediary approach enables simultaneous smoothing and finishing operations, reducing the overall processing time compared to sequential ironing and cooling methods, while also eliminating safety concerns associated with open flames.
3Manufacturing precision
If layer height is reduced to minimize stair-stepping effect, then surface finish improves, but build time increases significantly
Solution Approach 1:
The patent applies thermal-mechanical processing as a preliminary or post-processing step that corrects the surface finish issue without requiring changes to the primary manufacturing parameters. Instead of reducing layer height during printing (which would extend build time), the system prints at standard layer heights and then applies heat and rolling pressure to smooth the resulting surface. This preliminary smoothing action achieves fine surface finish while maintaining efficient standard printing speeds, resolving the contradiction between surface quality and build time.
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 provides a superior surface finish to 3D printed parts, making them suitable for bioprocessing equipment, reducing the likelihood of biofilm development within the bioprocessing system, thereby reducing the likelihood of damaging sensitive cell-based products.
Implementation Method 1
heating the contact surface to a temperature above the melting temperature of a material of the 3D printed part, thereby melting the surface to form a molten layer of the material at the surface
Implementation Method 2
allowing the surface to cool such that the molten layer formed at the surface re-solidifies, thereby producing a treated surface
Data Source
AI summary
The present disclosure relates to a method (1900) for surface treatment of 3D printed parts for bioprocessing equipment, the method comprising: applying (1902) pressure to a surface (210) to be treated of a 3D printed part (200) using a contact surface (111) of an elastomeric resurfacing tool (110); heating (1904) the contact surface (111) to a temperature above the melting temperature of a material of the 3D printed part (200), thereby melting the surface (210) to form a molten layer of the material at the surface (210); allowing (1906) the surface (210) to cool such that the molten layer formed at the surface (210) re-solidifies, thereby producing a treated surface; and withdrawing (1908) the pressure applied to the treated surface.