3D Printed Resistivity Control for Embedded Electrical Features
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Solution Overview
Problem
Current 3D printing technologies face challenges in integrating electrically conductive features and components into 3D objects, such as managing electrostatic discharge and creating complex electronic components, while existing methods often require multiple printing agents and processes.
Innovation Solution
An additive manufacturing system and method that uses a single printing agent to create both electrically conductive and non-conductive components by varying the saturation levels of the printing agent, allowing for the formation of 3D objects with embedded electrical circuitry and electrostatic discharge coatings, using a controller to control the deposition of build material and energy source to achieve desired resistivity levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple printing agents and processes are used to create electrically conductive features, then the conductivity control is improved, but the device complexity and manufacturing process complexity increase
Solution Approach 1:
The patent combines multiple printing agents (conductive agent and non-conductive agent) into a single multi-functional printing agent that can be deposited in varying saturation levels. This single agent system replaces what would traditionally require separate printing processes for conductive and non-conductive features, thereby reducing device complexity while maintaining the ability to control conductivity through saturation variation.
Solution Approach 2:
The printing agent is designed to serve multiple functions: it can create electrically conductive features when applied at higher saturation levels and electrically non-conductive features when applied at lower saturation levels. This multi-functionality eliminates the need for separate specialized printing agents for conductive and non-conductive components, simplifying the overall printing system while preserving precise conductivity control capabilities.
2Ease of manufacture
If a single printing agent is used for both conductive and non-conductive components, then the manufacturing process is simplified, but the precision of conductivity control may be compromised
Solution Approach 1:
The patent applies the local quality principle by varying the saturation level of the single printing agent at different locations on the build material layer. By controlling the concentration of conductive particles locally through saturation adjustment, the system achieves precise conductivity control in specific regions while maintaining process simplicity. High saturation areas produce conductive features, while low saturation areas produce non-conductive features.
Solution Approach 2:
The system controls conductivity precision by changing the saturation parameter of the printing agent rather than using different agents. The controller adjusts the saturation level of conductive particles in the printing agent based on the desired electrical properties, enabling precise control over the conductivity of printed features while using a single multi-functional printing material.
3Manufacturing precision
If varying saturation levels of printing agent are used, then the electrical properties (conductivity/resistivity) are precisely controlled, but the manufacturing process complexity increases
Solution Approach 1:
The system incorporates feedback control where the controller receives data defining the desired electrical properties of the build object and automatically adjusts the saturation level of the printing agent accordingly. This feedback mechanism translates design requirements for conductivity or resistivity into precise deposition parameters, enabling accurate control of electrical properties without requiring complex manual intervention or multiple specialized processes.
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 the creation of 3D objects with precise control over conductivity and resistivity, allowing for the integration of electrical components like capacitors, resistors, and conductive traces, effectively managing electrostatic discharge and achieving desired electronic properties within the 3D build object.
Implementation Method 1
print data is defined to print a second portion of the printing agent onto the build material layer in a select pattern of the electrical circuitry component of the build object. The printing agent at the select pattern is deposited at a second saturation level, the second saturation level being at or above the predetermined level for electrical conductivity.
Implementation Method 2
a printhead is controlled to dispense the printing agent onto the build material layer based on the generated print data. Fusing energy is applied to form the object layer including the electrical circuitry component
Data Source
AI summary
Some examples include an additive manufacturing build object including an electrical component and a build object body. The electrical component having a varying electrical resistivity within a resistivity range of 109 ohms per square to 105 ohms per square, the resistivity range obtained by an application and fusing of a fusing component of a printing agent and build material, the printing agent applied to the build material at a predetermined saturation dosage range corresponding to the resistivity range. The build object body having a second electrical resistivity obtained by an application and fusing of the fusing component of the printing agent and the build material, the printing agent applied at a dosage below the predetermined saturation dosage range, the build object body being electrically non-conductive.