Additive Manufacturing Consolidation via Curable Liquid Pressure

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for consolidating additively manufactured pieces are complex, time-consuming, and expensive, often requiring pre-manufactured molds that do not perfectly fit the piece, especially for complex geometries, and lack the ability to assemble or connect pieces without chemical links.

Innovation Solution

A method involving placing the piece in a thermally conductive container, filling it with a curable liquid or semi-liquid material that contacts and surrounds the piece, sealing the cavity, curing the material to create a pressure-molding effect, and heating it to consolidate the piece without a pre-manufactured mold, allowing for complex geometries and assembly of multiple pieces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If pre-manufactured molds are used to consolidate additively manufactured pieces, then the consolidation process can be performed, but the process becomes complex, time-consuming, and expensive, and the molds do not perfectly fit complex geometries

Engineering Contradiction:

Improvefitting precisionVSAvoidconsolidation process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent creates a digital 3D model of the additively manufactured piece and uses this digital copy to generate a customized consolidation tool path. This digital copying approach eliminates the need for physical pre-manufactured molds, allowing the consolidation process to perfectly match the piece's complex geometry while reducing process complexity and cost.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent changes the approach from using fixed physical molds to using programmable robotic end effectors with adjustable parameters. The consolidation parameters (pressure, temperature, motion path) can be dynamically modified through software to match any complex geometry, eliminating the need for custom-molded tools for each piece.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If pre-manufactured molds are used for consolidation, then consolidation can be achieved, but the process is time-consuming and expensive

Engineering Contradiction:

Improveconsolidation qualityVSAvoidconsolidation process time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

By using digital 3D models to generate consolidation tool paths, the system eliminates time-consuming physical mold manufacturing steps. The digital copying approach allows immediate program generation and execution, significantly reducing lead time while maintaining consistent consolidation quality through precise digital control.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the mechanical mold-based consolidation system with a robotic system controlled by software. This substitution eliminates the time required for physical mold fabrication and adjustment, while maintaining consolidation quality through programmable precision control of the robotic end effector.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If traditional consolidation methods are used, then pieces can be consolidated, but they cannot be assembled or connected without chemical links

Engineering Contradiction:

Improvepiece connection strengthVSAvoidassembly simplicity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces chemical bonding methods with a mechanical consolidation approach using a robotic end effector that applies controlled pressure and heat. This mechanical system can join multiple pieces together through direct physical contact and compression, eliminating the need for chemical links while maintaining connection strength and simplifying the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method simplifies and cost-reduces the consolidation process, enables precise fitting and pressure application for complex geometries, and allows for the assembly and connection of pieces without chemical links, improving their integrity.

Implementation Method 1

heating the cavity, wherein while the temperature is increased, the cured material expands and then creates a pressure on the part

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

curing the material, so that the cured material restricts the movement of the piece in the cavity

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Implementation Method 3

placing the piece in a cavity of a thermally conductive container

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12168314B2Method for consolidating an additively manufactured piece

Publication Date: 2024.12.17 9T LABS AG

AI summary

Methods and systems for consolidating an additively manufactured piece. In one embodiment, methods include the step of combining the additively manufactured piece with another piece, for example with another additively manufactured piece or with a piece that is not additively manufactured (e.g. an insert, foam, etc.), so that during a consolidation step, those pieces are assembled or connected together.