3D Printed Ultrasonic Probe Encapsulation via Stereolithography
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Solution Overview
Problem
The manual assembly of ultrasonic probes requires significant labor and time, leading to manufacturing variations and inefficiencies in the production process.
Innovation Solution
The ultrasonic probe is manufactured using 3D printing (stereolithography) where functional layers are deposited directly on the ultrasonic transducer, encapsulating it within a protective housing, reducing the need for manual assembly and variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual assembly is used to assemble multiple components around the ultrasonic source, then the ultrasonic probe can be constructed with functional components, but the manufacturing process requires significant labor and time, leading to manufacturing variations
Solution Approach 1:
The patent merges multiple separate manufacturing steps (depositing base layer, positioning transducer, depositing functional layers, forming housing) into a single integrated 3D printing process. The ultrasonic transducer is positioned within the build chamber, and all surrounding layers are deposited sequentially in one continuous manufacturing cycle, eliminating manual assembly operations and reducing manufacturing variations.
Solution Approach 2:
The 3D printing system automatically performs positioning and assembly operations that would otherwise require manual intervention. The build platform moves automatically to position the transducer, and the deposition system automatically applies functional layers at precise locations, enabling the manufacturing process to service itself without human labor during assembly.
2Productivity
If multiple components are assembled manually around the ultrasonic source, then the probe can be constructed, but the process introduces manufacturing variations and requires significant manual labor
Solution Approach 1:
The patent replaces manual mechanical assembly operations with an automated 3D printing system. The deposition mechanism uses computer-controlled material extrusion or deposition to build layers automatically, substituting human hands and tools with automated robotic or mechanical systems that can operate continuously without fatigue or variation.
Solution Approach 2:
The manufacturing process is segmented into discrete automated layers that are deposited sequentially. Each layer (base layer, first functional layer, second functional layer, housing) is built independently in controlled segments, allowing the complex assembly to be broken down into manageable automated steps that can be executed precisely by the 3D printing system.
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 method reduces manual assembly time and variations, enabling the production of ultrasonic probes with improved consistency and efficiency through direct layer deposition on the transducer.
Implementation Method 1
focusing a first light beam within a volume of the base material resin adjacent to a surface of the platform, and curing the volume of base material resin in response to exposure to the first light beam
Data Source
AI summary
An ultrasonic probe and methods of manufacture are provided. The method can include depositing a base layer on a platform. The method can also include depositing a first portion of a first functional layer on the base layer. The method can further include positioning a first surface of an ultrasonic transducer on the first portion of the first functional layer. The transducer can further include a second surface opposite the first surface and opposed first and second sides. The first and second sides can be transverse to the first and second surfaces. The method can additionally include depositing a second portion of the first functional layer on the first and second sides of the transducer. The method can further include depositing a second functional layer upon the second surface of the transducer. The transducer can be encapsulated by the first functional layer and the second functional layer.