Energy Emitters With Absorbing Back Panels for Build-Layer Fusion

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Solution Overview

Problem

Existing 3D printing processes face issues with improper coalescing of build material particles due to variable energy reflection, leading to uneven energy distribution and potential defects in the formed 3D objects.

Innovation Solution

The apparatus includes a back panel to absorb reflected energy, transparent panels with anti-reflective coatings, and reflective elements to control energy distribution, ensuring targeted heating of build material particles without re-supplying reflected energy, using energy emitters that emit different wavelengths to achieve precise fusion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If energy emitters are used to heat build material particles for fusion, then the build material particles can be coalesced to form 3D objects, but variable energy reflection from the particles causes improper coalescing and uneven energy distribution

Engineering Contradiction:

Improvecoalescing precisionVSAvoidenergy distribution uniformity

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

An energy absorber is introduced as an intermediary component between the energy emitters and the build material particles. This absorber intercepts reflected energy that would otherwise return to the particles and cause uneven heating. The absorber converts the reflected energy into heat and dissipates it, preventing the harmful re-supply of reflected energy to the build material particles.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The solution converts the harmful reflected energy into a beneficial effect by using the energy absorber to capture the reflected energy and convert it into controlled heat. This prevents the reflected energy from causing improper coalescing while utilizing it as an additional heat source that can be managed through the absorber's thermal properties.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Use of energy by moving object

If reflected energy is allowed to return to build material particles, then energy efficiency may be improved, but improper coalescing and defects occur due to variable energy reflection patterns

Engineering Contradiction:

Improveenergy efficiencyVSAvoidcoalescing uniformity

Core Design Contradiction:

Use of energy by moving objectVSManufacturing precision

Solution Approach 1:

The energy absorber serves as a mediator that intercepts reflected energy before it can return to the build material particles. This prevents the variable energy reflection patterns from causing improper coalescing while still allowing the system to maintain high energy efficiency by controlling where the reflected energy is directed and dissipated.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If energy emitters apply high energy levels to fuse particles quickly, then productivity increases, but overheating and defects occur due to excessive energy concentration

Engineering Contradiction:

Improvefusion speedVSAvoidoverheating

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The energy absorber acts as a thermal buffer and mediator that prevents excessive energy concentration on the build material particles. By intercepting and redistributing the thermal energy, the absorber ensures that high energy levels can be applied for rapid fusion without causing localized overheating or defects in the coalesced material.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 controlled energy application, preventing overheating and reducing defects in 3D objects by maintaining consistent energy levels at selected locations, thereby improving the quality of the fabrication process.

Implementation Method 1

The apparatus may include a back panel that may absorb energy, e.g., energy reflected back into the apparatuses from the build material particles.

Methodology Applied

Scientific EffectEnergy absorption: Absorption (EM radiation)

Implementation Method 2

Energy in the form or radiation, such as light, may be used in 3D printing processes to heat build material particles and/or a binding agent

Methodology Applied

Scientific EffectElectromagnetic radiation heating: Thermal Radiation

Implementation Method 3

the build material particles may receive energy at levels that may exceed intended levels because the amount of energy reflected back onto the build material particles may be based on the pattern at which fusing and/or binding agent has been deposited

Methodology Applied

Scientific EffectEnergy absorption: Absorption (EM radiation)

Data Source

PatentUS12441059B2Energy emitting apparatuses for build material layers

Publication Date: 2025.10.14 PERIDOT PRINT LLC

AI summary

According to examples, an apparatus may include a back panel to absorb energy and an energy emitter to supply energy onto a build material layer. The energy emitter may include an energy emitting element and an outer tube. In addition, a reflective element may be provided on a portion of the outer tube facing the back panel to direct energy away from the back panel. The apparatus may also include a transparent panel, in which energy from the energy emitter may be emitted through the transparent panel and onto the build material layer.