Additive-Ablative Fabrication for High-Resolution Open-Air Curing
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Solution Overview
Problem
Conventional solid free form fabrication (SFF) techniques face challenges with oxygen inhibition during curing, particularly in atmospheric environments, leading to reduced coating properties and uncured surfaces, especially with low-intensity curing processes like UV LED or UVA cure, which result in sticky surfaces.
Innovation Solution
The method combines additive manufacturing with selective ablation using a laser beam, achieving high resolution (less than 16 μm) and allowing for the use of various materials, including ceramics, metals, and plastics, with the option to embed foreign elements, and operates in an open space for improved fabrication speed and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional curing processes are used in atmospheric environment, then the curing process can be performed simply, but oxygen inhibition occurs leading to reduced coating properties and uncured surfaces
Solution Approach 1:
The patent employs an inert gas environment (such as nitrogen or argon) during the UV curing process to displace oxygen from the curing zone. This prevents oxygen inhibition of the photopolymerization reaction, allowing complete curing of the material surface while maintaining process simplicity. The inert atmosphere creates an oxygen-free environment that enables the curing process to proceed without the harmful effects of atmospheric oxygen.
2Use of energy by moving object
If low-intensity curing processes like UV LED or UVA are used, then energy consumption is reduced, but oxygen inhibition is exacerbated resulting in sticky uncured surfaces
Solution Approach 1:
The patent applies an inert gas atmosphere specifically during low-intensity UV LED or UVA curing processes to eliminate oxygen inhibition. This allows these energy-efficient curing methods to achieve complete surface curing without the sticky, uncured surface problems that normally occur with low-intensity processes in atmospheric conditions.
Solution Approach 2:
The inert gas acts as an intermediary medium between the UV light source and the curable material surface. It creates a protective environment that allows the low-intensity UV radiation to effectively cure the material without oxygen interference, bridging the gap between low energy input and high curing quality.
3Manufacturing precision
If material is dispensed at high resolution, then fabrication precision is improved, but fabrication speed decreases
Solution Approach 1:
The patent segments the fabrication process into distinct stages: high-speed material dispensing at lower resolution followed by selective laser ablation at high resolution. This segmentation allows each process to operate at its optimal speed and precision level, with the laser ablation step removing material to achieve the final high-resolution geometry without requiring the entire dispensing process to run at high resolution.
Solution Approach 2:
Instead of dispensing material precisely where it should remain (traditional approach), the patent inverts the logic by dispensing material more liberally and then using laser ablation to remove material where it should not be. This inverse approach allows faster dispensing speeds while still achieving high-resolution final geometry through the subtractive laser processing step.
4Manufacturing precision
If selective ablation is performed to achieve high resolution, then manufacturing precision is improved, but process complexity increases
Solution Approach 1:
The patent employs a laser system that serves multiple functions: material ablation for high-resolution geometry, curing of photopolymerizable materials, and potentially heating or drying operations. This multi-functional laser approach consolidates what would otherwise require separate equipment into a single system, reducing overall device complexity while maintaining high manufacturing precision through selective ablation.
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 provides improved resolution, speed, and versatility in fabricating 3D objects from diverse materials, enabling the embedding of electronic devices and achieving high precision in electrical conductive patterns without the limitations of oxygen inhibition, enhancing the overall SFF process.
Implementation Method 1
selective ablation using a laser beam
Implementation Method 2
curing of a monomer
Data Source
AI summary
A printer pressing assembly for forming material layers is provided. The printer pressing assembly includes a support assembly having a support surface, a driver and a press stop. The driver is able to change an elevation of the support surface relative to an elevation of the press stop. A nozzle is capable of dispensing a material onto the support surface. Further, a press is positionable opposite to the support surface and capable of moving relative to the support. Additionally, the press stop is capable of being elevated above the support surface so as to engage an abutment surface of the press to set a pre-determined distance between the contact surface of the press and the support surface.