3D Printed Object Stitching with Curable Compliant Material
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Solution Overview
Problem
Additive manufacturing (AM) techniques produce 3D printed objects with inferior mechanical properties compared to conventional methods, particularly due to high anisotropic behavior, heterogeneity, and poor adhesion between layers, leading to localized deformation and detachment issues.
Innovation Solution
Introducing reinforcing structures, such as channels filled with a low-stiffness, curable material during the 3D printing process, which act as stitches or anchors to improve mechanical integrity and prevent delamination, while being embedded within the object to maintain appearance and surface smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional additive manufacturing is used to produce 3D printed objects, then manufacturing flexibility and rapid prototyping are improved, but mechanical properties and structural integrity deteriorate due to anisotropic behavior and poor layer adhesion
Solution Approach 1:
The patent applies composite materials by combining the base AM material with a curable compliant material (such as polymeric or metal-filled materials) that is injected into cavities and cured to form reinforcing structures. This composite approach leverages the flexibility of AM manufacturing while compensating for its mechanical weaknesses through the addition of strengthening materials, thereby achieving both manufacturing flexibility and improved mechanical properties simultaneously
Solution Approach 2:
The patent implements local quality by strategically placing reinforcing structures only in specific regions where mechanical strength is needed. The curable material is injected into cavities at predetermined locations to create localized reinforcement zones, allowing the rest of the component to maintain its lightweight and flexible AM characteristics while critical areas gain enhanced mechanical properties
2Strength
If reinforcing structures are added to improve mechanical properties, then strength and structural integrity are improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent applies preliminary action by creating cavities for reinforcing structures during the initial AM manufacturing process rather than adding them as separate post-processing steps. The cavities are formed as part of the base structure, and the curable material is then injected and cured in-situ, integrating the reinforcement addition into the manufacturing workflow and reducing overall process complexity
Solution Approach 2:
The patent merges the reinforcing structure addition with the base component manufacturing by using the same AM process to create both the base structure with cavities and the final reinforced structure. The curable material is injected into pre-formed cavities and cured, combining what would traditionally be separate manufacturing operations into a unified process that improves structural integrity without proportionally increasing complexity
3Strength
If stitches or reinforcing structures are inserted to prevent fiber detachment and layer delamination, then mechanical integrity is improved, but surface smoothness and appearance deteriorate due to visible stitching
Solution Approach 1:
The patent applies the nested doll principle by embedding the reinforcing structures within the bulk material of the AM component. The curable material is injected into internal cavities and cured to form reinforcing elements that are nested within the component's interior, providing mechanical integrity enhancement while keeping the external surface smooth and free of visible stitching or protrusions
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 enhances the strength and out-of-plane mechanical properties of 3D printed objects by inhibiting delamination and providing a reinforcing structure that is not visible from the outside, thus improving the overall structural integrity and appearance.
Implementation Method 1
For 3D inkjet printing or dispensing, a liquid monomer mixture may be used and by photo polymerization the shape is then fixed before the following layer is deposited
Data Source
AI summary
The invention provides a method for the production of a 3D printed object (100), wherein the method comprises (i) a 3D printing stage, the 3D printing stage comprising 3D printing a 3D printable material (110) to provide the 3D printed object (100) of printed material (120), wherein the 3D printing stage further comprises forming during 3D printing a channel (200) in the 3D printed object (100) under construction, wherein the method further comprises (ii) a filling stage comprising filling the channel (200) with a curable material (140) and curing the curable material (140) to provide the channel (200) with cured material (150), wherein the cured material (150) has a lower stiffness than the surrounding printed material (120).