3D Printed Electronic Parts Thermal Management
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Solution Overview
Problem
Current 3D printing techniques require multiple steps and specialized equipment to build and embed electronics within dense parts, often resulting in inefficient processes and suboptimal electronic properties due to uncontrolled thermal distribution and material activation procedures.
Innovation Solution
The method employs multi-jet fusion (MJF) with electronic, fusing, and detailing agents, using electromagnetic radiation to selectively fuse build material layers, managing thermal distribution through multiple printing passes and heating events to achieve desired electronic properties and mechanical strength, while controlling cooling to prevent overheating and thermal bleed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional 3D printing techniques are used to build and embed electronics, then electronics can be integrated into dense parts, but the process requires multiple steps and specialized equipment resulting in inefficiency
Solution Approach 1:
The patent combines multiple functions (electronic agent application, fusing agent application, and heating) into a single integrated printing head and process cycle. The printing head simultaneously deposits electronic agents, fusing agents, and detailing agents onto the build material layer, which is then selectively heated to fuse the material and activate electronic properties in one coordinated operation, eliminating the need for multiple separate steps and specialized equipment
Solution Approach 2:
The printing head is designed as a multi-functional device that can deposit multiple types of agents (electronic, fusing, detailing) and the system can perform both structural building and electronic property integration in a single process, making the equipment universal for both mechanical and electronic manufacturing tasks
2Manufacturing precision
If electromagnetic radiation is used to fuse build material, then material can be selectively fused, but thermal distribution must be precisely controlled to prevent overheating and thermal bleed
Solution Approach 1:
The patent applies different types of agents (electronic, fusing, detailing) to different regions of the build material layer, and the heating process is selectively applied only to regions containing fusing agents. This localized approach ensures that thermal energy is concentrated only where needed to fuse the material, preventing overheating and thermal bleed to surrounding areas while achieving precise fusing control
Solution Approach 2:
The fusing agents act as intermediaries that absorb electromagnetic radiation and convert it to thermal energy at specific locations. This intermediary mechanism allows precise spatial control of heat generation, enabling selective fusing of build material only in regions where fusing agents are present, thereby controlling thermal distribution and preventing unwanted heating
3Reliability
If multiple printing passes and heating events are used to manage thermal distribution, then desired electronic properties and mechanical strength can be achieved, but the process time increases
Solution Approach 1:
The patent employs periodic heating events interspersed with printing passes, where the system alternates between depositing agent layers and applying electromagnetic radiation for selective fusing. This periodic cycle allows thermal management by cooling between heating events while maintaining progress, achieving reliable electronic properties and mechanical strength through controlled thermal cycles rather than continuous heating
Solution Approach 2:
The patent applies electronic agents, fusing agents, and detailing agents to the build material layer before the heating event occurs. This preliminary application ensures that when heating is applied, the agents are already in position to perform their functions (activating electronic properties, enabling selective fusing, controlling thermal distribution), thereby achieving the desired quality outcomes in the first heating cycle without requiring multiple corrective passes
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
This approach enables the production of 3D printed electronic parts with suitable conductivity, insulation, and mechanical strength, maintaining an aesthetically pleasing surface finish by precisely managing thermal processes and agent application, resulting in parts that exhibit at least 80% of bulk material properties.
Implementation Method 1
The agents are capable of penetrating into the layer of the build material and spreading onto the exterior surface of the build material. The activated electronic agent and/or the fusing agent is capable of absorbing electromagnetic radiation and converting the absorbed radiation to thermal energy
Implementation Method 2
This in turn melts or sinters the build material that is in contact with the activated electronic agent and/or the fusing agent
Implementation Method 3
This in turn melts or sinters the build material that is in contact with the activated electronic agent and/or the fusing agent
Data Source
AI summary
In an example method for forming three-dimensional (3D) printed electronic parts, a build material is applied. An electronic agent is selectively applied in a plurality of passes on a portion of the build material. A fusing agent is also selectively applied on the portion of the build material. The build material is exposed to radiation in a plurality of heating events. During at least one of the plurality of heating events, the portion of the build material in contact with the fusing agent fuses to form a region of a layer. The region of the layer exhibits an electronic property. An order of the plurality of passes, the selective application of the fusing agent, and the plurality of heating events is controlled to control a mechanical property of the layer and the electronic property of the region.