3D Printing Process Pressure and Strain Control
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Solution Overview
Problem
Existing three-dimensional object production techniques face challenges in reliability when dealing with objects having different structural portions and the use of various solidifying materials, particularly due to difficulties in managing pressure, strain, and material flowability during the solidification process.
Innovation Solution
A process and device that involve sensing and adjusting pressure, strain, contact pressure, fluid pressure, and material flowability in real-time within the building region, using sensors and controllers to optimize the solidification process by controlling parameters such as movement distance, pressure force, separation force, and material flowability, ensuring accurate and reliable production of three-dimensional objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If known solid freeform fabrication techniques are used to produce three-dimensional objects, then objects can be manufactured with complex geometries, but reliability deteriorates when objects have different structural portions (mass portions vs. delicate portions) or when auxiliary support structures are involved
Solution Approach 1:
The patent applies local quality by differentiating the treatment of different structural portions within the same object. The system adjusts process parameters (energy density, layer thickness, scanning speed) based on the local structural characteristics - using parameters optimized for mass portions in one area and different parameters for delicate portions in another area, thereby maintaining high reliability across diverse structural requirements
Solution Approach 2:
The patent implements dynamics by making the manufacturing process adaptive and variable rather than static. The system dynamically adjusts process parameters during manufacturing based on real-time conditions and pre-defined structural characteristics, allowing the same system to reliably produce both mass portions and delicate portions by changing operational parameters mid-process
2Adaptability or versatility
If conventional solidification techniques are used, then manufacturing can be performed with standard equipment, but it becomes difficult to adopt different types or compositions of solidifying materials
Solution Approach 1:
The patent achieves universality by designing a manufacturing system that can handle multiple types and compositions of solidifying materials through a unified approach. The system uses a standardized energy supply interface and controllable solidification process that works across different material types (polymers, ceramics, metals), allowing one device to perform multiple material processing functions without requiring completely different equipment for each material type
Solution Approach 2:
The patent applies parameter changes by systematically varying energy supply parameters (intensity, duration, distribution) and process parameters (temperature, pressure, atmosphere) to accommodate different material compositions. This allows the same basic system to adapt to various materials by adjusting controllable parameters rather than requiring fundamental system changes
3Reliability
If pressure and strain conditions are not monitored during solidification, then the device structure can be simpler, but reliability and quality of the produced object deteriorate
Solution Approach 1:
The patent implements feedback by incorporating sensors that monitor pressure and strain conditions during the solidification process and using this information to adjust process parameters in real-time. This closed-loop control ensures that critical conditions are maintained within optimal ranges, thereby improving reliability while the added monitoring complexity is justified by the quality improvements
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 enhances the reliability of three-dimensional object production by accurately managing critical conditions during solidification, reducing damage to the device and the object, and allowing for the use of a wider variety of solidifying materials, thereby improving the overall system's performance and reducing defects.
Implementation Method 1
supplying, to the building region, energy capable of solidifying the solidifiable material
Data Source
AI summary
A process for producing at least one three-dimensional object by solidifying a solidifyable material, comprising the steps of: providing an object carrier capable of carrying the object to be produced; providing a material capable of solidifying when subjected to energy supply; bringing a solidifyable material carrier/provider in a position to carry/provide solidifyable material at least in a building region where solidifyable material is to be solidified; supplying, to the building region, energy capable of solidifying the solidifyable material; and sensing, measuring and/or controlling a condition selected from the group consisting of pressure and/or strain. Alternatively or in combination, contact pressure, fluid pressure and/or material flowability can be sensed and/or adjusted.