3D Printing Temperature Sensor Embedding and Pyrometer Intermediary
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Solution Overview
Problem
Existing 3D printing systems face inaccuracies in temperature determination due to variations in surface finish and content of the printed material, which can affect the bonding properties of layers.
Innovation Solution
A system and method involving a 3D printer that deposits layers with a temperature sensor, such as a thermocouple, embedded within the layers to accurately measure the temperature of the object being printed, allowing for precise temperature control and bonding optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a pyrometer is used to measure temperature non-contact, then the 3D printing process is not obstructed, but the temperature determination becomes inaccurate due to surface finish and content variations
Solution Approach 1:
The patent introduces an intermediary substance (liquid metal or paste containing metal particles) that is applied to the surface of the object being printed. This intermediary provides a consistent, emissive surface that the pyrometer can accurately measure, while the underlying material properties remain unchanged. The intermediary acts as a mediator between the pyrometer and the varying surface conditions of the printed object.
Solution Approach 2:
The patent changes the surface parameters (emissivity, reflectivity) by applying a substance with known and consistent thermal radiation properties. This allows the pyrometer to operate under standardized conditions regardless of the varying surface characteristics of the printed material, effectively decoupling the measurement accuracy from the surface finish variations.
2Measurement precision
If a temperature sensor is embedded within the layers, then accurate temperature measurement is achieved, but the device complexity increases
Solution Approach 1:
The 3D printing process itself is used to deposit and position the temperature sensor within the layers. The printing system automatically places the sensor in the correct location during normal operation, eliminating the need for separate manual installation steps. The system serves itself by integrating sensor deployment into the existing manufacturing process.
Solution Approach 2:
The patent combines the temperature sensing function with the structural layers of the printed object. The sensor becomes an integral part of the object's internal architecture, merged with the layers during the printing process. This integration reduces the number of separate components and simplifies the overall system configuration.
3Adaptability or versatility
If the surface finish and content of printed material vary, then the printing process is flexible, but the pyrometer temperature measurements become inaccurate
Solution Approach 1:
The applied liquid metal or paste serves as a universal intermediary that standardizes the surface properties regardless of the underlying material variations. This intermediary layer provides consistent emissivity characteristics that enable accurate pyrometer measurements across different material types, surface finishes, and printing conditions, effectively decoupling measurement accuracy from material variability.
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 accurate temperature measurement and control, ensuring optimal bonding properties between layers and improving the overall quality of the printed object.
Implementation Method 1
The temperature sensor is configured to measure a temperature of the first layer of material, the second layer of material, the third layer of material, or a combination thereof
Implementation Method 2
One type of non-contact temperature sensor that is used is called a pyrometer, which measures an emissivity of a surface of the object during the 3D printing process. The emissivity refers to an effectiveness of emitting heat energy as thermal radiation.
Data Source
AI summary
A system for determining a temperature of an object includes a three-dimensional (3D) printer configured to successively deposit a first layer of material, a second layer of material, and a third layer of material to form the object. The 3D printer is configured to form a recess in the second layer of material. The material is a metal. The system also includes a temperature sensor configured to be positioned at least partially with the recess and to have the third layer deposited thereon. The temperature sensor is configured to measure a temperature of the first layer of material, the second layer of material, the third layer of material, or a combination thereof.