Additive Manufacturing Cure Control via Localized Energy Delivery
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Solution Overview
Problem
Current additive manufacturing techniques using curable feedstocks face challenges in achieving optimal adhesion between layers, leading to parts prone to separation or deformation due to inconsistent curing, which affects the quality and mechanical properties of the final product.
Innovation Solution
The system employs a curing energy source that actively delivers energy to discrete sections of the part during manufacturing, allowing for controlled curing profiles to impart specific mechanical properties, enabling precise control over the level of cure, duration, and intensity of curing energy to different sections, thereby tailoring the properties of the part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If full curing is provided to the material as it is being deposited, then the material achieves complete cure and structural integrity, but the adhesion between adjacent layers deteriorates causing separation and peeling
Solution Approach 1:
The patent applies different curing levels to different spatial locations and layers of the part. The controller directs the curing energy source to provide varying degrees of cure to discrete sections, allowing fully cured regions for structural integrity while maintaining partially cured regions for better layer adhesion and flexibility.
Solution Approach 2:
The curing process is made dynamic by adjusting curing parameters in real-time during deposition. The controller modifies curing energy intensity, duration, and distribution based on the current build state, enabling adaptation between full cure requirements and adhesion preservation needs as manufacturing progresses.
2Strength
If too little cure is provided to the material, then layer adhesion is maintained, but the part becomes prone to deformation and undesirable properties
Solution Approach 1:
Different regions of the part are assigned different target cure levels based on their functional requirements and structural importance. Critical load-bearing sections receive higher cure levels for deformation resistance, while non-critical areas maintain lower cure levels to preserve adhesion and flexibility.
Solution Approach 2:
The system performs preliminary curing at controlled levels during the deposition process itself, rather than applying full cure post-manufacturing. This allows the part to develop sufficient structural stability incrementally while maintaining adhesion properties throughout the build process.
3Ease of manufacture
If uniform curing is applied to the entire part, then the manufacturing process is simple, but the mechanical properties cannot be tailored to individual section needs
Solution Approach 1:
The part is divided into discrete sections or regions, each with independently controllable curing parameters. The controller manages multiple curing zones with different energy levels, durations, and patterns, enabling spatially varying mechanical properties while maintaining a unified manufacturing process.
Solution Approach 2:
The system varies curing parameters (energy intensity, exposure duration, wavelength, scan speed) across different regions and time points during manufacturing. This parametric control enables customization of mechanical properties for different part sections without fundamentally changing the additive manufacturing process architecture.
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 ensures consistent and desired mechanical properties, reducing deformation and improving adhesion between layers, allowing for the creation of parts with tailored characteristics, such as enhanced temperature resistance and durability.
Implementation Method 1
Current additive manufacturing techniques that utilize curable feedstock materials, such as photopolymers, typically provide full curing of the material as it is being deposited by a nozzle, such as by directing a light source directly at the outlet of the nozzle.
Data Source
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Figure 3
AI summary
Systems (10) for cure control of additive manufacturing comprise a build volume (12), a curing energy source (16), and a controller. The curing energy source (16) is configured to actively deliver curing energy (18) to discrete sections of a part (14) as it is being additively manufactured. The controller is programmed to direct delivery of curing energy (18) to impart desired cure properties to the discrete sections and/or according to predetermined cure profiles for the discrete sections. Methods of additively manufacturing a part (14) comprise additively building a part (14) from a feedstock material, and actively curing discrete sections of the part (14) as it is being additively built to impart desired cure properties to the part (14) and/or desired cure profiles to the part (14).