3D Printing with Yield-Stress Colloid Support Bath
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Solution Overview
Problem
Current 3D printing techniques face limitations such as nozzle clogging, difficulty in printing support structures, and interfacial strength issues between layers, particularly when using ionically cross-linkable materials, which restrict the wide use of traditional solidification/curing/gelation approaches.
Innovation Solution
A 'printing-then-solidification' methodology utilizing a Laponite nanoclay yield-stress colloid as a support bath, where the support material transitions from a gel-like to a free-flow state and back, allowing for the printing of complex structures without phase change until the entire structure is fabricated, eliminating the need for rapid solidification and support baths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional solidification/curing/gelation approaches are used during printing, then layer-by-layer structure formation is enabled, but nozzle clogging and interfacial strength issues occur
Solution Approach 1:
The patent separates the solidification process from the printing process. The build material is printed in liquid form without immediate solidification, and only after the entire structure is printed does a phase change occur to solidify the material. This segmentation eliminates nozzle clogging during printing and ensures uniform interfacial strength throughout the structure.
Solution Approach 2:
The patent applies a preliminary action by printing the complete liquid structure first before applying any solidification treatment. The entire three-dimensional liquid structure is formed and positioned correctly, then a phase change is induced throughout the structure to solidify it, ensuring uniform properties throughout.
2Stability of the object's composition
If rapid solidification is used to maintain structural integrity during printing, then layer stability is improved, but printing speed and complexity are reduced
Solution Approach 1:
The patent extracts the solidification step from the printing process. Instead of solidifying each layer immediately after deposition, the system allows the entire structure to be printed in liquid form first, then applies a single phase change treatment to the complete structure. This eliminates the constraint of rapid solidification and enables faster, more complex printing.
3Strength
If support material is used during printing to maintain structure, then structural support is provided, but support material removal and contamination issues arise
Solution Approach 1:
The patent utilizes a parameter change in the build material itself - transitioning from liquid to solid phase after printing. The build material maintains liquid properties during printing (allowing free flow and positioning) then undergoes a phase change to solidify, providing structural support inherently without requiring separate support materials that would need removal.
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
Enables the printing of complex structures with various build materials by maintaining structural integrity and allowing for precise control of features, while avoiding nozzle clogging and interfacial strength issues, and facilitating easy removal of the support material post-printing.
Implementation Method 1
the support material has a gel-like state when a stress applied to the support material is less than a yield stress, wherein the support material has a free-flow state when the stress applied to the support material is above the yield stress
Implementation Method 2
a printing device for delivering a plurality of discrete volumes of a liquid to the support bath, wherein each discrete volume of liquid can be delivered to a specified voxel
Implementation Method 3
the support material flows out of each specified voxel as the discrete volume of the liquid build material can be printed to each specified voxel, wherein after each discrete volume of the liquid build material can be printed to each specified voxel, the support material in the free-flow state transforms back to the gel-like state
Data Source
AI summary
Embodiments of the present disclosure provide for three dimensional printing apparatuses, methods of three dimensional printing, and the like.