3D Printed Surface Finishing With Pulsed Radiation Heating
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Solution Overview
Problem
3D printed objects from multi-jet fusion processes often have rough surfaces due to poor surface flatness and partially melted powder particles, which degrade their optical appearance and can lead to distortion when attempting to uniformly melt the surface.
Innovation Solution
An apparatus and method that apply a controlled pulse of radiation to selectively melt and flow the outer surface of the 3D printed object, using a radiation source and controller to heat only the surface region, filling voids and integrating excess powder particles without distorting the object by maintaining the interior at a lower temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If uniform heating is applied to melt the surface of the 3D printed object, then the surface smoothness is improved, but the object becomes distorted
Solution Approach 1:
The patent applies radiation with a spatially varying intensity distribution where the radiation intensity is highest at the surface and decreases toward the interior. This creates a temperature gradient that is highest at the surface (melting and smoothing it) while keeping the interior temperature below the melting point (preventing distortion), thus resolving the contradiction between surface smoothness and shape integrity
Solution Approach 2:
The patent uses pulsed radiation rather than continuous heating. The pulsed nature allows controlled energy delivery that melts the surface layer while the brief duration prevents heat diffusion to the interior that would cause distortion, achieving surface smoothing without shape change
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 solution effectively smooths the surface of 3D printed objects, improving their optical appearance and preventing distortion, as demonstrated by significant reduction in surface roughness and uniform color without altering the object's shape.
Implementation Method 1
apply a pulse of radiation onto the 3D printed object that is of sufficient intensity to cause an outer portion of the 3D printed object to begin to melt and flow
Implementation Method 2
cause an outer portion of the 3D printed object to begin to melt and flow
Data Source
AI summary
According to an example, in a method, a radiation source that is to output radiation at a preset energy level onto a surface of a three-dimensional (3D) printed object may be activated. In addition, the radiation source may be deactivated after a predefined period of time sufficient to cause an outer portion of about a predetermined thickness of the surface of the 3D printed object to begin to melt to finish the surface of the 3D printed object.