3D Printing Liquid Functional Agent for Thermal Control
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Solution Overview
Problem
Current 3D printing technologies face limitations in controlling the heating and cooling rates of build materials, which affects the microstructure and physical properties of printed parts, such as hardness, tensile strength, and surface finish, due to the lack of precise control over phase nucleation and growth during the printing process.
Innovation Solution
The use of a liquid functional agent containing an energy source material that undergoes an exothermic reaction, allowing for localized control of heating and cooling rates through inkjet technology, enabling customized physical properties on a voxel scale by selectively applying the agent and oxidizer to the build material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional heating methods are used in 3D printing, then the build material can be heated to required temperatures, but precise control of heating and cooling rates is not achieved, resulting in poor microstructure control
Solution Approach 1:
The patent applies local quality by using inkjet technology to selectively deposit liquid functional agents containing energy source materials at specific locations within the build material. This enables spatially varying heating and cooling rates, allowing different regions of the printed part to have customized microstructures tailored to specific performance requirements.
Solution Approach 2:
The patent implements parameter changes by utilizing liquid functional agents with varying compositions, concentrations, and thermal properties. By adjusting the type and amount of energy source material in the liquid functional agent, the heating and cooling rates can be precisely controlled to achieve desired microstructural outcomes in different regions of the build material.
2Manufacturing precision
If uniform heating is applied to the build material, then the entire material reaches the required temperature, but localized control over phase nucleation and growth is not achieved
Solution Approach 1:
The patent replaces conventional mechanical heating systems with a chemically-based approach using liquid functional agents. The energy source materials in these agents undergo exothermic reactions to generate heat locally, eliminating the need for complex mechanical heating and cooling systems while achieving precise localized control over phase transformations.
Solution Approach 2:
The liquid functional agent acts as an intermediary carrier that delivers energy source materials to specific locations in the build material. This intermediary enables controlled local heating through chemical reactions, providing a simpler alternative to direct mechanical heating while maintaining precise spatial control over the heating process.
3Productivity
If high heating rates are used to reduce printing time, then productivity increases, but control over cooling rates and microstructure development is lost
Solution Approach 1:
The patent applies preliminary action by incorporating energy source materials into liquid functional agents that are deposited into the build material before final heating. These pre-positioned energy sources enable controlled exothermic reactions during subsequent heating, allowing rapid heating while maintaining control over the thermal process and resulting microstructure.
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 allows for the precise control of microstructure and physical properties of 3D printed parts by varying the cooling rates, resulting in parts with tailored structural integrity and surface finish, enhancing the overall quality and versatility of 3D printing.
Implementation Method 1
a liquid functional agent containing an energy source material that undergoes an exothermic reaction
Implementation Method 2
through inkjet technology, enabling customized physical properties on a voxel scale by selectively applying the agent and oxidizer to the build material
Implementation Method 3
affects the microstructure and physical properties of printed parts, such as hardness, tensile strength, and surface finish, due to the lack of precise control over phase nucleation and growth during the printing process
Data Source
Figure 1
Figure 2
Figure 3A~4B
AI summary
In a three-dimensional printing method example, a liquid functional agent is selectively applied. The liquid functional agent includes i) an energy source material or ii) an energy sink material. A metallic or ceramic build material is applied. The liquid functional agent is selectively applied any of before the metallic or ceramic build material, after the metallic or ceramic build material, or both before and after the metallic or ceramic build material. The liquid functional agent patterns the metallic or ceramic build material to form a composite layer. At least some of the metallic or ceramic build material is exposed to energy. A reaction involving i) the energy source material or ii) the energy sink material is initiated to alter a thermal condition of the composite layer.