Additive Manufacturing of Green Bodies with UV-Thermal Curing

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Solution Overview

Problem

Existing additive manufacturing methods, such as DLS and CLIP, face issues with excessive heating during UV radiation, leading to viscosity changes and partial curing of construction materials, which affect the quality and mechanical properties of three-dimensional objects.

Innovation Solution

A method involving controlled UV exposure to form a green body, followed by thermal curing, where the UV exposure is managed to avoid exceeding the curing temperature, allowing for separate curing reactions to occur during thermal processing, utilizing materials with different curing behaviors to enhance mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If UV radiation is applied to cure construction material, then solidification speed is improved, but temperature increases causing viscosity changes and partial curing

Engineering Contradiction:

Improvesolidification speedVSAvoidcuring temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The curing process is divided into two distinct stages: first UV radiation for rapid initial solidification, then thermal energy for complete curing. This segmentation allows each method to optimize its function without the harmful effects of the other

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies UV radiation in a controlled, periodic manner during the first solidification step, then transitions to thermal energy in a second step. This periodic application of different energy types prevents excessive temperature buildup while maintaining curing effectiveness

Inventive Principle:

Principle #19Periodic action

2Productivity

If UV radiation exposure is increased to improve solidification, then manufacturing speed is improved, but thermal energy introduction increases causing harmful heating effects

Engineering Contradiction:

Improvemanufacturing speedVSAvoidheating effect

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The manufacturing process is segmented into two steps: UV-based rapid solidification followed by thermal curing. This allows high-speed UV exposure without excessive heating, as the thermal effects are managed in the second step with controlled energy input

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a second curing component that acts as an intermediary, requiring thermal energy to activate. This component remains dormant during UV exposure, allowing rapid UV solidification without triggering full curing and associated heating, then completes the process thermally

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If thermal energy is applied to cure construction material, then complete solidification is achieved, but manufacturing time increases

Engineering Contradiction:

Improvesolidification completenessVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

UV radiation is applied first to perform preliminary solidification, creating a green body with sufficient structural integrity. This preliminary action reduces the subsequent thermal curing time required to achieve complete solidification, thereby reducing total manufacturing time while ensuring completeness

Inventive Principle:

Principle #10Preliminary action

4Strength

If construction material contains multiple components with different curing behaviors, then mechanical properties are improved, but process complexity increases

Engineering Contradiction:

Improvemechanical propertiesVSAvoidprocess complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent changes the curing parameter from a single method to two sequential methods (UV then thermal). The construction material is formulated with components having different activation thresholds, allowing selective curing based on energy type. This parameter differentiation enables enhanced mechanical properties through dual network formation while maintaining relatively simple process control

Inventive Principle:

Principle #35Parameter changes

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 precise mechanical properties and improved quality of three-dimensional objects by minimizing thermal curing during UV exposure, enabling the formation of distinct polymer networks and enhancing mechanical performance.

Implementation Method 1

successive, in particular layer-by-layer, selective exposure and solidification of a construction material comprising at least one UV-curable component by means of UV radiation

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Implementation Method 2

subjecting the green body to thermal energy, wherein at least one component of the construction material thermally cures when a curing temperature is exceeded

Methodology Applied

Scientific EffectThermal curing:

Data Source

PatentUS12434441B2Method for additive manufacturing of a three-dimensional object

Publication Date: 2025.10.07 BAYERISCHE MOTOREN WERKE AG

AI summary

A method for additive manufacturing of a three-dimensional object includes successively exposing a construction material having at least one UV-curable component by UV radiation to form a green body and subjecting the green body to thermal energy, where at least one component of the construction material thermally cures to form the three-dimensional object upon exceeding of a curing temperature. The successively exposing by the UV radiation to form the green body is controlled such that at least in sections the curing temperature of the at least one component is not significantly exceeded.