3D Printed Object Hardness Control Using Electro-Curing Feedback
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Solution Overview
Problem
Current 3D printing techniques face limitations in efficiently creating objects with varying hardness levels, requiring material changes and setup delays, which hinder manufacturing efficiency and effective bonding between different materials.
Innovation Solution
A method that uses a low-level electrical voltage and controlled duration to achieve target hardness levels in printed objects, allowing for dynamic adjustment of hardness without changing materials or nozzles, utilizing electro-curing materials and ultrasonic measurement for real-time feedback to ensure precise hardness control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If material changes are made to achieve different hardness levels in 3D printing, then the hardness variation requirement is met, but setup time and manufacturing efficiency deteriorate
Solution Approach 1:
The patent changes the electrical voltage parameter applied to the printing material to control hardness levels. By adjusting voltage intensity and exposure time, different hardness levels are achieved without changing materials or nozzles, thus maintaining manufacturing efficiency while meeting hardness variation requirements
Solution Approach 2:
The patent makes a single printing material capable of producing multiple hardness levels through electrical voltage treatment. This universal approach eliminates the need for multiple specialized materials and nozzle configurations, resolving the contradiction between achieving hardness variation and maintaining productivity
2Manufacturing precision
If multiple materials are used to achieve different hardness levels, then the hardness requirement is satisfied, but device complexity and setup activity increase
Solution Approach 1:
Instead of using multiple materials with different properties, the patent uses parameter changes (electrical voltage intensity and exposure time) on a single material to achieve different hardness levels, significantly reducing device complexity
Solution Approach 2:
The patent extracts the hardness control function from material selection and nozzle configuration, transferring it to an electrical voltage treatment process. This separation simplifies the printing system while maintaining the ability to produce varied hardness levels
3Ease of manufacture
If traditional 3D printing without electrical voltage is used, then manufacturing process simplicity is maintained, but hardness control precision deteriorates
Solution Approach 1:
The patent introduces electrical voltage as a controllable parameter that can be precisely adjusted to achieve specific hardness levels. The voltage intensity and exposure time are optimized to provide precise hardness control while maintaining relatively simple manufacturing processes
Solution Approach 2:
The patent replaces traditional mechanical hardness control methods (material changes, temperature adjustments) with an electrical field-based approach. This substitution enables more precise and controllable hardness levels while keeping the overall process relatively simple
4Productivity
If electrical voltage is applied to control hardness, then manufacturing efficiency is improved, but energy consumption increases
Solution Approach 1:
The patent applies electrical voltage only to specific regions of the printing material that require hardness modification, rather than treating the entire material. This partial application reduces overall energy consumption while maintaining manufacturing efficiency benefits
Solution Approach 2:
The electrical voltage is applied in controlled time intervals during the printing process, with specific exposure durations optimized to achieve the desired hardness effect. This periodic application minimizes energy consumption while maintaining productivity improvements
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 manufacturing of objects with varying hardness levels by eliminating the need for material changes and setup delays, improving manufacturing efficiency and ensuring stable bonding between different materials.
Implementation Method 1
measuring during a printing of the printed material to the print object, the level of hardness for the portion of the print object, by use of an ultrasonic device
Implementation Method 2
applying, during 3D printing of the print object, a pre-determined set of parameters including an electrical voltage and a duration of applying the electrical voltage to the printed material
Data Source
AI summary
A method for variable hardness within three-dimensional (3D) printing. Metadata associated with a print object as a 3D printing copy of an original object is received, the metadata includes data indicating a level of hardness of a portion of the print object. During 3D printing set of parameters including a voltage and a duration are applied to the printing material, such that the level of hardness associated with the metadata of the original object is attained. During printing, the level of hardness is measured using an ultrasonic device, and responsive to determining the level of hardness of the portion of the print object differs from the metadata associated with the portion of the original object, the set of parameters for the portion of the print object are adjusted to attain a target level of hardness as indicated by the metadata of the original object.