Additive-Ablative 3D Fabrication for Oxygen-Free UV 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 and system combine additive manufacturing with selective ablation using a laser beam, achieving high resolution and speed, allowing for the use of various materials and embedding foreign elements, with the option to perform the process in an open space, enabling improved lateral and vertical resolution and embedding capabilities.

Engineering Contradictions & Design Principles

VSEngineering 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

Engineering Contradiction:

Improvecuring process simplicityVSAvoidsurface curing quality

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent employs an inert atmosphere (nitrogen or argon) to displace oxygen during the UV curing process, eliminating oxygen inhibition and enabling complete curing of the photoresist material while maintaining process simplicity

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Use of energy by moving object

If low-intensity curing processes like UV LED or UVA cure are used, then energy consumption is reduced, but oxygen inhibition is exacerbated resulting in sticky uncured surfaces

Engineering Contradiction:

Improvecuring energy consumptionVSAvoidsurface curing completeness

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

By creating an oxygen-free inert atmosphere, the patent enables low-intensity UV LED or UVA curing processes to achieve complete curing without oxygen inhibition, maintaining both low energy consumption and high curing reliability

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Device complexity

If additive manufacturing is used for high-resolution features, then fabrication complexity increases, but selective ablation provides simpler high-resolution fabrication

Engineering Contradiction:

Improvefabrication process complexityVSAvoidlateral resolution

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent replaces complex multi-material additive manufacturing systems with a simpler selective ablation process using laser or plasma to remove sacrificial material, achieving high lateral resolution through energy beam precision rather than mechanical deposition complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Adaptability or versatility

If conventional additive manufacturing is used, then material selection is limited, but selective ablation enables use of diverse materials including ceramics and metals

Engineering Contradiction:

Improvematerial diversityVSAvoidvertical resolution

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The inert atmosphere enables selective ablation of diverse materials including ceramics, metals, and polymers with controlled vertical resolution, as the oxygen-free environment prevents unwanted oxidation and allows precise energy beam interaction with different material types

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

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 and fabrication speed, enabling the creation of high-resolution 3D objects from diverse materials, including ceramics, metals, and conductive patterns, while allowing for the embedding of electronic devices within the fabrication process, overcoming the limitations of oxygen inhibition and atmospheric curing challenges.

Implementation Method 1

selectively ablating the first material layer with a laser beam to form a two-dimensional pattern

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

The laser beam causes the first material layer to ablate where the laser beam strikes the surface of the first material layer

Methodology Applied

Scientific EffectAblation: Ablation

Implementation Method 3

curing the second material with the laser beam, wherein the curing causes the second material to solidify

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS11420397B2Method and system for additive-ablative fabrication

Publication Date: 2022.08.23 IO TECH GRP LTD

AI summary

A method for solid free form fabrication includes providing a dispensing head, printing one or more support material layer(s) with the dispensing head and forming vacancies within the one or more support material layer(s), and filling the vacancies within the one or more support material layer(s) with a modeling material. The method also includes straightening the modeling material with a leveler to form a three-dimensional shaped object and removing at least a portion of the one or more support material layer(s) from the three-dimensional shaped object.