3D Surface Patterning by Tomographic Light Grafting
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Solution Overview
Problem
Current methods for surface modification of complex 3D objects are limited to two-dimensional surfaces, are expensive, slow, and do not enable uniform and highly controlled surface patterns required for many devices, especially when introducing a second polymer through a covalent bond.
Innovation Solution
A volumetric additive manufacturing (VAM) process that uses tomographic 3D printing to selectively pattern a surface of a solid object with a multifunctional material covalently bonded to the surface, utilizing patterned light to initiate grafting of the multifunctional material, which can be done in one-step or two-step processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photolithography or chemical vapor deposition is used for surface modification, then uniform surface patterns can be achieved, but the method is limited to two-dimensional surfaces and complex 3D geometries cannot be accessed
Solution Approach 1:
The patent transitions from two-dimensional surface modification techniques to three-dimensional volumetric modification by immersing the object in a liquid composition and using light propagation through the liquid to pattern the surface. This allows uniform patterning on complex 3D geometries by enabling light access to all surfaces regardless of shape complexity.
2Manufacturing precision
If two photon polymerization or direct laser writing is used to fabricate complex 3D surface patterns, then highly controlled patterns can be achieved, but the process is expensive and slow with print times taking hours
Solution Approach 1:
The patent replaces the mechanical point-by-point laser scanning system with a volumetric light projection system using digital micromirror devices (DMD) or spatial light modulators (SLM). This substitution enables parallel processing of the entire surface simultaneously, reducing patterning time from hours to minutes while maintaining high precision through computational control of light distribution.
Solution Approach 2:
The patent performs preliminary preparation by immersing the object in a liquid composition containing photoinitiator and functional monomers before light exposure. This pre-saturation of the surface with reactive components allows rapid polymerization upon light exposure, eliminating the need for slow sequential material deposition and enabling fast patterning.
3Adaptability or versatility
If overprinting is used to introduce a second polymer structure, then 3D objects can be modified, but uniform and highly controlled surface patterns cannot be achieved and covalent bonding is not established
Solution Approach 1:
The patent introduces a liquid composition as an intermediary medium containing photoinitiator and functional monomers. This liquid medium penetrates and saturates the porous surface structure of the object, enabling uniform distribution of reactive components across complex geometries. The liquid intermediary facilitates controlled polymerization and covalent bonding that cannot be achieved through direct vapor or solution-phase deposition alone.
Solution Approach 2:
The patent changes the physical state and composition parameters by using a liquid composition with specific photoinitiator concentrations and monomer types. By adjusting these parameters and controlling light exposure dose, the system achieves precise control over polymerization extent, surface pattern uniformity, and covalent bonding efficiency, transforming the modification process from uncontrolled overprinting to precision surface engineering.
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 fast and cost-effective surface patterning on complex geometries with defined locations, providing robust and securely coated layers of multifunctional materials, allowing for a broad range of surface properties and materials, and enabling applications such as anti-fogging, anti-microbial, hydrophobic/hydrophilic surfaces, and complex electronic components.
Implementation Method 1
selectively irradiating the composition at the surface of the solid base object with patterned light, the irradiating being tomographic, to initiate covalent grafting of the multifunctional material to the surface of the solid base object
Data Source
AI summary
A volumetric additive manufacturing (VAM) process for producing a solid object having a surface layer of a multifunctional material patterned thereon involves: contacting a surface of a solid base object with a liquid composition containing a photo-initiator and a multifunctional material covalently graftable to the surface of the solid base object; and, selectively irradiating the composition at the surface of the solid base object with patterned light, the irradiating being tomographic, to initiate covalent grafting of the multifunctional material to the surface of the solid base object to pattern only a portion of the surface of the solid base object with a layer of the multifunctional material grafted thereon, where the portion of the surface of the solid base object corresponds to the selectively irradiated surface of the solid base object.