3D Printing Thermal Compression to Reduce Filament Voids
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Solution Overview
Problem
Current three-dimensional printing apparatuses using the fused deposition modeling method suffer from voids between filaments, which degrade the mechanical properties of the modeled body.
Innovation Solution
A three-dimensional printing apparatus and method that includes a mechanism to continuously feed a printing material through a nozzle, a table for stacking the material, a heating member for thermal compression, and a control unit to manage these components. The apparatus forms a sheet-like material layer and then compresses it using the heating member during relative movement between the table and the heating member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If filaments are arranged closely together in a continuous manner and formed into a sheet, then the manufacturing efficiency is improved, but voids occur between the filaments degrading the mechanical properties
Solution Approach 1:
The patent applies thermal compression by changing the temperature parameter of the printing material. The heating member heats the printing material to a softened state, enabling the material to flow and fill voids between filaments, thereby improving mechanical properties while maintaining continuous manufacturing efficiency
Solution Approach 2:
The patent utilizes phase transition of the printing material from solid to softened state through heating. This phase change allows the material to become pliable and fill gaps between filaments, eliminating voids while maintaining the continuous layer formation process
2Strength
If a heating member is added to compress the material layer, then the mechanical properties are improved, but the device complexity increases
Solution Approach 1:
The patent merges the heating function and compression function into a single integrated heating member. This combination eliminates the need for separate heating and compression mechanisms, reducing device complexity while achieving both thermal softening and mechanical compression to improve mechanical properties
3Strength
If the printing material is compressed during stacking, then the adhesive strength between materials is increased, but the energy consumption increases
Solution Approach 1:
The patent uses phase transition (melting/softening) of the printing material through controlled heating to enable compression. The material transitions to a softened state during compression, requiring less energy than compressing solid material, and then solidifies to provide strong adhesive bonds between layers
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
The proposed solution reduces the number of voids between filaments and enhances the adhesive strength, thereby improving the mechanical properties of the modeled body.
Implementation Method 1
a third mechanism that includes a heating member
Implementation Method 2
heating and softening filaments made of a thermoplastic resin
Implementation Method 3
a thermal compression mechanism including a heating member, and the thermal compression mechanism is configured to compress a sheet-like material layer
Data Source
Figure 1
Figure 2(a)~2(b)
Figure 3~4
AI summary
In a three-dimensional printing apparatus, a printing material (F) supplied from a nozzle (64) is disposed along a printing path, and a sheet-like material layer (FL) configured with a single layer or a plurality of layers is formed. The material layer (FL) is compressed by a heating member (81) while performing relative movement between a table (3) and the heating member (81).