3D Printing Post-Treatment for Localized Material Properties
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Solution Overview
Problem
Existing methods for producing three-dimensional objects by layer-by-layer solidification of construction materials often fail to achieve desired properties efficiently, particularly in terms of special component properties, and are costly or impractical.
Innovation Solution
A method and device for producing three-dimensional objects by selectively solidifying layers of building material, where at least a sub-area of the solidified material is post-treated to change specific material properties, such as electrical conductivity, optical properties, or mechanical properties, using different radiation or field exposure, allowing for localized changes within the object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If selective laser sintering or laser melting is used to produce three-dimensional objects, then layer-by-layer solidification can be achieved, but the process is expensive and cannot produce objects with desired special properties
Solution Approach 1:
The patent applies preliminary action by introducing a post-treatment step during the manufacturing process. After the object is built layer-by-layer, specific regions are selectively post-treated to achieve desired special properties such as enhanced strength, conductivity, or surface finish. This allows the base manufacturing process to remain simple while adding functionality through targeted subsequent treatment.
Solution Approach 2:
The patent implements local quality by enabling different regions of the three-dimensional object to receive different post-treatments. Specific sub-regions can be selectively treated to achieve locally optimized properties, while other regions maintain their base characteristics. This allows the object to have spatially varying properties tailored to functional requirements.
2Reliability
If the entire solidified area is post-treated to change material properties, then uniform property enhancement is achieved, but production time and energy consumption increase significantly
Solution Approach 1:
The patent applies local quality by enabling selective post-treatment of only specific sub-regions within the solidified area. Instead of treating the entire area uniformly, the system can target only those regions requiring property enhancement, thereby maintaining production efficiency while achieving the necessary material properties in critical areas.
Solution Approach 2:
The patent implements partial action by applying post-treatment to only the necessary portions of the solidified material rather than the entire area. This selective approach achieves the required material properties in critical regions without the time and energy penalty of treating the whole object, optimizing the balance between reliability and productivity.
3Productivity
If minimal energy is introduced during selective solidification to maintain flexibility, then layer-by-layer building is efficient, but the resulting object has high porosity and low strength
Solution Approach 1:
The patent applies preliminary action by using minimal energy during the initial selective solidification to maintain high building speed and flexibility. The object is efficiently constructed with acceptable base properties, and then strength enhancement is achieved through subsequent post-treatment of specific regions, separating the building efficiency function from the strength optimization function.
Solution Approach 2:
The patent implements parameter changes by varying the energy input at different stages: minimal energy during selective solidification to maintain productivity, and enhanced energy during post-treatment to improve strength. This staged parameter adjustment allows the system to optimize for building speed initially, then enhance mechanical properties where needed.
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 three-dimensional objects with varied material properties within the same object, such as increased conductivity or transparency, by introducing minimal energy during solidification and additional energy during post-treatment, or by removing material to create cavities, resulting in enhanced rigidity, strength, or complex conductor structures.
Implementation Method 1
selectively solidifying the applied layer by solidifying an area of the applied layer corresponding to a cross-section of the object in the layer to form a solidified area in the layer
Implementation Method 2
solidifying the deposited layer by solidifying an area of the deposited layer corresponding to the cross-section of the object in the layer
Implementation Method 3
During post-treatment within the scope of the invention, energy is then introduced again, so that the powder now melts better and the component achieves greater rigidity or strength at selected post-treated points
Implementation Method 4
a possible procedure within the scope of the invention is explained in more detail below using a selected example: Only relatively little energy is introduced in the step of selective solidification
Data Source
AI summary
The invention relates to a method for producing a three-dimensional object (2) by applying construction material (15) in layers and selectively solidifying same, having the step of applying a layer of the construction material (15) onto a construction base (10, 11, 12) within a construction field (8) and the step of selectively solidifying the applied layer by solidifying a region of the applied layer, said region corresponding to the cross-section of the object (2) in the layer, in order to produce a solidified region in the layer. The application and selective solidification steps are repeated until the three-dimensional object (2) is completed. A sub-region which is only one pre-determined part of the solidified region is post-treated at least once during the production of the three-dimensional object (2). The sub-region lies substantially in the interior of the solidified region.