3D Printing Electrical Circuits on Curved Surfaces
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Solution Overview
Problem
Existing methods for manufacturing on-body electronics are difficult and error-prone, as they require multiple steps to attach conductive materials to flexible substrates, which are inherently two-dimensional, while the human body is a three-dimensional surface, limiting the direct printing of electric circuits on complex body positions.
Innovation Solution
A 3D printing apparatus and method that adjusts two-dimensional electric circuit information to match the three-dimensional shape of the target surface, generating a tool path for the ink supply unit to print conductive ink directly on the body, allowing for flexible and accurate placement of electric circuits on various body parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two-dimensional stickers or tattoos are used for on-body electronics, then the manufacturing process is simplified, but the accuracy and fit on three-dimensional body surfaces deteriorates
Solution Approach 1:
The patent transitions from two-dimensional circuit designs to three-dimensional printing that directly adapts to the body's curved surfaces. The 3D printing apparatus deposits conductive material layer-by-layer following the target surface geometry, enabling accurate circuit placement on three-dimensional body parts while maintaining manufacturing simplicity through direct digital printing.
2Manufacturing precision
If multiple manufacturing steps are used to attach conductive materials to flexible substrates, then the circuit can be manufactured with higher precision, but the manufacturing complexity and error rate increase
Solution Approach 1:
The patent combines multiple manufacturing steps into a single 3D printing operation. The system simultaneously performs circuit design, path planning, and material deposition in one integrated process, eliminating separate steps for substrate attachment and circuit fabrication. This reduces manufacturing complexity and error rates while maintaining precision through digital control.
Solution Approach 2:
The 3D printing system automatically adapts the circuit path to match the target body surface geometry without requiring manual intervention for substrate attachment or alignment. The apparatus self-adjusts to the three-dimensional shape, performing what would traditionally require multiple manual assembly steps.
3Device complexity
If traditional 2D printing methods are used, then the printing device structure is simpler, but the ability to print on various body positions and 3D surfaces is limited
Solution Approach 1:
The patent employs a dynamic printing system where the 3D printing apparatus can move and adapt its printing head to follow complex body contours and reach various body positions. The system dynamically adjusts the printing path in three-dimensional space, enabling versatile placement on different body parts while maintaining a relatively simple apparatus structure through software-controlled motion planning.
Data Source
AI summary
A method and apparatus for printing an electric circuit directly on a target surface having a three-dimensional shape are provided. In this method, a 3D printing apparatus that can be attached to a target surface is used. In this printing method, two-dimensional information about the shape of the electric circuit to be printed and information about the three-dimensional shape of the target surface are input. Two-dimensional information about the shape of the electric circuit to be printed is adjusted based on the information about the three-dimensional shape of the target surface to generate three-dimensional information about the electric circuit to be printed. Based on this, a tool path for controlling the 3D printing apparatus is generated.An electric circuit can be directly fabricated on a target surface having a three-dimensional shape by the method and apparatus. In addition, an electronic device having a three-dimensional electric circuit manufactured by the present method can be applied in various ways.