Additive Foam Manufacturing Gradient Properties
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Solution Overview
Problem
Current methods for producing foam parts through additive manufacturing struggle to create materials with gradient properties throughout a single continuous part while maintaining correct dimensions, and existing processes are inefficient and time-consuming.
Innovation Solution
The use of a layer-by-layer additive manufacturing process that selectively melts regions of pulverant via electromagnetic energy, incorporating thermoplastic polyurethane polymer (TPU) coated on low-density base particles, along with additives like glass beads and metal oxides, to produce foam parts with tailored properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional foam production methods (injection molding, continuous dispensing) are used, then foam parts can be produced, but they cannot achieve gradient properties throughout a single continuous part while maintaining correct dimensions
Solution Approach 1:
The patent applies local quality by incorporating additives (glass beads, metal oxides) at specific concentrations within the pulverant to create gradient properties in different regions of the foam part. The AMF file controls the spatial distribution of these additives to achieve desired property variations while maintaining overall dimensional accuracy through layer-by-layer fabrication.
Solution Approach 2:
The patent segments the foam production process into layer-by-layer deposition, allowing different additive concentrations to be introduced at different layers. This segmentation enables gradient properties to be built up systematically while each layer maintains precise dimensional control through controlled material deposition.
2Productivity
If conventional foam production processes are used, then foam can be manufactured, but the processes are inefficient and time-consuming
Solution Approach 1:
The patent implements continuous production through the layer-by-layer additive manufacturing process, where material is continuously deposited and fused according to the AMF file without interruption. This continuous fabrication eliminates the need for separate foam production and assembly steps, significantly reducing manufacturing time and improving productivity.
Solution Approach 2:
The patent changes the manufacturing parameters by using controlled deposition rates, temperature profiles, and additive distribution patterns to optimize the fabrication process. These parameter adjustments enable faster production while maintaining foam quality and gradient properties, addressing the efficiency-time contradiction.
3Reliability
If elastomeric materials are used in additive manufacturing, then desirable mechanical, thermal, or electrical properties can be provided, but density, hardness, compression set, and rebound are compromised
Solution Approach 1:
The patent creates composite foam materials by combining elastomeric pulverant with specific additives (glass beads, metal oxides) at controlled concentrations. This composite approach allows the base elastomeric material to provide mechanical properties while the additives modify density, hardness, and other characteristics, achieving a balance between reliability and precision.
Solution Approach 2:
The patent applies local quality by varying the concentration and distribution of additives within different regions of the foam part. This enables different areas to have optimized properties for their specific functions, allowing density and hardness to be precisely controlled in certain regions while maintaining overall elastomeric performance.
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 enables the rapid production of foam parts with continuous elastomeric properties, allowing for gradient properties throughout the part and precise dimensions, improving efficiency and flexibility in various applications.
Implementation Method 1
regions of respective layers of pulverant are selectively melted via introduction of electromagnetic energy
Data Source
AI summary
The disclosed exemplary apparatuses, systems and methods provide a three-dimensional foam molding, produced via a layer-by-layer additive manufacturing process in which regions of respective layers of pulverant are selectively melted via introduction of electromagnetic energy. These apparatuses, systems and methods may include layers of the pulverant comprising at least thermoplastic polyurethane polymer (TPU) coated upon a base particle, wherein the TPU is coated via one of spray drying and a fluidized vessel.