3D Printing Surface Smoothing via Compensation Droplets
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Solution Overview
Problem
Existing three-dimensional printing methods require post-processing steps to achieve a smooth surface, which increases manufacturing time and costs due to the need for additional tools and precise positioning.
Innovation Solution
A method that deposits multiple droplets of printing material side by side and one above the other, followed by targeted placement of compensation droplets to smooth the surface, allowing for in-printer reworking and eliminating the need for external post-processing tools, using UV curable monomers or polymers with varying viscosities and curing techniques to achieve a smooth surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If post processing steps (grinding, sanding, waterblasting, lacquering) are used to smooth the surface of printed structures, then the surface quality is improved, but the manufacturing time and costs increase due to additional tools and positioning requirements
Solution Approach 1:
The patent applies preliminary action by smoothing the surface during the printing process itself rather than after completion. Compensation droplets are deposited and cured in advance to eliminate edges and irregularities, so the surface is already smooth when the printing is finished, eliminating the need for subsequent post-processing steps
Solution Approach 2:
The patent merges the printing process with the smoothing process into a single integrated operation. The compensation droplets are deposited using the same printing system that created the pre-structure, combining the structure formation and surface smoothing functions in one process rather than requiring separate post-processing equipment
2Manufacturing precision
If post processing steps are used to smooth the surface of printed structures, then the surface quality is improved, but the manufacturing costs increase due to additional tools and positioning requirements
Solution Approach 1:
The printing system performs self-service by using its own capabilities to smooth the surface. The compensation droplets are deposited and cured by the same printing apparatus that created the pre-structure, allowing the system to correct its own output without requiring external post-processing equipment
Solution Approach 2:
The printing system is made multi-functional, serving both to create the three-dimensional pre-structure and to smooth its surface. The same printing apparatus performs both the primary printing function and the surface compensation function, eliminating the need for dedicated post-processing tools
3Manufacturing precision
If the printed article is inserted into an additional post processing tool, then the surface is smoothed, but the positioning and orientation accuracy requirements increase
Solution Approach 1:
The smoothing action is performed preliminarily during the printing process itself, before the article is completed. The compensation droplets are deposited and cured in advance to eliminate edges and irregularities, so no subsequent positioning into post-processing tools is required
Solution Approach 2:
The positioning and smoothing functions are merged into the single printing process. The printing system inherently knows where to deposit compensation droplets based on the pre-structure geometry, eliminating the need for separate positioning operations into post-processing equipment
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 reduces manufacturing time and costs by smoothing the surface directly during the printing process, eliminating the need for external post-processing and ensuring high-quality smooth surfaces without additional tools or positioning requirements.
Implementation Method 1
curing the deposited droplets by light irradiation to build up a three-dimensional pre-structure
Implementation Method 2
smoothing at least one surface of the three-dimensional pre-structure by targeted placement of compensation droplets in boundary areas of adjacent deposited droplets and/or in edges of the surface to be smoothed
Data Source
AI summary
The present invention relates to a method for printing a three-dimensional structure with a smooth surface comprising the following steps of depositing multiple droplets of printing material at least partially side by side and one above the other and curing the deposited droplets by light irradiation to build up a three-dimensional pre-structure in a first step, and smoothing at least one surface of the three-dimensional pre-structure by targeted placement of compensation droplets in boundary areas of adjacent deposited droplets and/or in edges of the surface to be smoothed in a second step to build up the three-dimensional structure with a smooth surface.