3D Printing With 450–1200 nm Selective Polymer Fusion

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Solution Overview

Problem

Existing 3D printing technologies face challenges in effectively fusing and crystallizing polymeric build materials, leading to agglomeration and deformation issues, which affect the quality and separation of 3D objects.

Innovation Solution

Utilizing a focused energy source that emits wavelengths between 450 nm and 1200 nm to selectively fuse polymeric build materials with a fusing agent, ensuring a high spectral selectivity ratio to prevent agglomeration and maintain mechanical integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional energy sources are used to fuse polymeric build materials, then the build material can be solidified, but agglomeration and deformation issues occur affecting quality

Engineering Contradiction:

Improvequality of 3D objectVSAvoidseparation of 3D objects

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent changes the parameter of energy wavelength from conventional broad-spectrum sources to a specific range (450-1200 nm) that matches the absorption characteristics of the fusing agent. This parameter change enables selective heating of the fusing agent without excessive heating of the polymeric build material, preventing agglomeration and deformation while ensuring proper fusion and crystallization.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies local quality by using a fusing agent with specific energy absorption properties that is selectively applied to the build material. The fusing agent creates localized zones of high energy absorption at the 450-1200 nm wavelength range, enabling precise control over which areas of the build material are fused and crystallized, thereby improving manufacturing precision and object separation.

Inventive Principle:

Principle #3Local quality

2Strength

If high energy is used to fuse build material, then fusion occurs, but agglomeration and deformation occur

Engineering Contradiction:

Improvefusion of build materialVSAvoiddeformation of build material

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The patent changes the energy parameter from high-intensity broad-spectrum energy to moderate-intensity energy within the 450-1200 nm wavelength range. This selective wavelength targeting allows the fusing agent to absorb energy efficiently and transfer it to the build material for fusion, while the build material itself absorbs less energy, preventing excessive heating that causes deformation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The fusing agent acts as an intermediary substance that mediates the energy transfer from the energy source to the polymeric build material. The fusing agent has high absorption efficiency at 450-1200 nm wavelengths, concentrating energy delivery to specific locations and controlling the fusion process, thereby preventing uncontrolled agglomeration and deformation of the build material.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If conventional wavelengths are used, then energy is delivered to build material, but spectral selectivity is low causing poor fusion control

Engineering Contradiction:

Improvecontrol of fusionVSAvoidenergy absorption efficiency

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent changes the wavelength parameter from conventional broad-spectrum energy sources to a specific range of 450-1200 nm. This parameter change creates high spectral selectivity where the fusing agent absorbs energy efficiently at these wavelengths while the polymeric build material absorbs less, enabling precise control over the fusion process and improving manufacturing precision.

Inventive Principle:

Principle #35Parameter changes

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 enables the production of 3D objects with improved mechanical properties by properly fusing and crystallizing polymeric materials, facilitating easy separation and reducing deformation risks.

Implementation Method 1

Utilizing a focused energy source that emits wavelengths between 450 nm and 1200 nm to selectively fuse polymeric build materials with a fusing agent

Methodology Applied

Scientific EffectSelective heating: Absorption (EM radiation)

Implementation Method 2

ensuring a high spectral selectivity ratio to prevent agglomeration and maintain mechanical integrity

Methodology Applied

Scientific EffectEnergy absorption: Absorption (EM radiation)

Implementation Method 3

causing the build material to melt, coalesce and then crystallize upon cooling

Methodology Applied

Scientific EffectMelting and crystallization: Phase Change

Data Source

PatentUS20250282101A13D printing using energy sources

Publication Date: 2025.09.11 PERIDOT PRINT LLC

AI summary

A three-dimensional (3D) printer and a method 3D printing are disclosed herein. The method of 3D printing includes receiving a print job data for a 3D object to be generated from a build material with a right limit temperature of the build material crystallization curve higher than a left limit temperature of the build material fusing curve of the build material. The method further includes generating a layer of the build material and selectively depositing an energy absorbent fusing agent to the layer of the build material based on the print job. Finally, the method includes emitting energy at a set of wavelengths in the range of 430 to 1200 nm to the layer of the build material to cause the build material on which the energy absorbent fusing agent was deposited to melt, coalesce, and then solidify upon cooling.