3D Printing Surface Quality via Pre-Treated Base Substrate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
3D printing or additive manufacturing faces challenges in achieving high surface quality on a large scale due to the intrinsic limitations of the method, making it difficult to produce consumer products with consistent finishes, as post-processing techniques are not intrinsic to the object itself.
Innovation Solution
The method involves selecting a base surface with predefined qualities to print the 3D object, minimizing capillary forces of the jetted material, and integrating electronic components, ensuring that the surface quality is imparted to the object during the printing process, using substances like glass, polyimide, and polycarbonate to achieve desired textures such as glassiness, smoothness, or roughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If post-processing techniques are applied to improve surface quality, then surface finish is improved, but manufacturing complexity and additional processing time are increased
Solution Approach 1:
The patent applies preliminary action by preparing the base surface with desired texture or finish characteristics before the 3D printing process begins. The base surface is pre-treated with substances like glass, polyimide, or polycarbonate to create the desired surface properties, which are then transferred to the printed object during printing, eliminating the need for post-processing surface treatment
Solution Approach 2:
The invention implements self-service by enabling the base surface itself to impart the desired surface quality characteristics directly to the printed object during the printing process. The surface treatment is built into the printing process rather than being applied separately, allowing the system to produce finished surfaces intrinsically without requiring external post-processing operations
2Productivity
If conventional 3D printing is used without base surface selection, then manufacturing speed is maintained, but surface quality consistency deteriorates
Solution Approach 1:
The patent applies local quality by selecting and preparing specific base surface regions with particular texture or finish characteristics that correspond to the desired surface quality areas of the printed object. Different portions of the base surface can have different treatments applied, allowing localized control of surface properties while maintaining overall manufacturing efficiency
Solution Approach 2:
The invention implements parameter changes by modifying the base surface parameters (texture, material composition, surface energy) before printing to achieve consistent surface quality outcomes. By controlling the base surface parameters and the interaction between jetted material and base surface, the process achieves repeatable surface quality characteristics across multiple production runs
3Ease of manufacture
If jetted material is applied on standard surfaces, then printing process is simple, but material seepage and surface defects increase
Solution Approach 1:
The patent applies the intermediary principle by introducing a specially prepared base surface as a mediator between the jetted printing material and the final object. This intermediate base surface layer prevents direct unwanted interaction between the material and standard surfaces, controlling material flow and preventing seepage while maintaining process simplicity
Solution Approach 2:
The invention implements this principle by using a disposable or replaceable base surface layer that is optimized for each printing run. The base surface can be prepared with specific treatments for each job and then discarded or regenerated, eliminating the need for complex reusable fixtures while ensuring consistent surface quality results
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 allows for the production of 3D printed objects with predetermined surface qualities, such as glassiness or smoothness, integrated electronic components, and reduced material seepage, enhancing the surface quality and integration of components within the object.
Implementation Method 1
selecting substances for the base that minimize capillary forces of the jetted printing material
Data Source
AI summary
A method of 3D printing to achieve a desired surface quality on at least one surface of a 3D printed object comprising selecting a base surface having the desired surface quality; and printing the 3D printed object on the base surface, so that the desired surface quality is imparted to one surface of the 3D printed object during printing. The surface quality may be glassiness, roughness, smoothness and texture in general. Objects may thus be manufactured in which electronic components are integrated in or under a glass-like surface.