Additive Manufacturing Structured Air Pockets

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Additive manufacturing methods face challenges in incorporating structured air pockets within objects without compromising their outer appearance, while reducing weight and material usage, and imparting desired mechanical properties, as existing techniques often result in deformation or incomplete enclosure of air pockets due to insufficient curing and material collapse.

Innovation Solution

The method involves defining and printing self-supporting structured air pockets with tapered ends and enhanced polymerization techniques, using materials with high photo-initiator concentrations and reflective materials, and filling air pockets with liquids to prevent oxygen inhibition, allowing continuous layer-wise deposition without interrupting the printing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of stationary object

If air pockets are incorporated into the object, then weight and material usage are reduced, but structural integrity and appearance may be compromised

Engineering Contradiction:

Improveobject weightVSAvoidstructural integrity

Core Design Contradiction:

Weight of stationary objectVSStrength

Solution Approach 1:

The patent incorporates structured air pockets (porous structures) within the object's internal volume to reduce weight and material usage. The air pockets are designed with specific geometries (spherical, cylindrical, or irregular shapes) and distributed throughout the object to maintain structural integrity while achieving weight reduction goals.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The object is segmented into multiple regions containing air pockets rather than being a solid continuous structure. This segmentation allows the object to maintain strength through strategic placement of support walls between air pockets while reducing overall material consumption.

Inventive Principle:

Principle #1Segmentation

2Quantity of substance

If air pockets are incorporated into the object, then material cost is reduced, but manufacturing precision may be compromised due to deformation and incomplete enclosure

Engineering Contradiction:

Improvematerial usageVSAvoidair pocket enclosure precision

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

Support walls are pre-designed and constructed before finalizing the air pocket enclosure structure. These support walls provide preliminary structural framework that prevents deformation during the additive manufacturing process, ensuring precise enclosure of air pockets without compromising manufacturing precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent employs parameter changes in the additive manufacturing process, including adjusting layer height, infill density, and support wall thickness, to achieve precise air pocket enclosure. By optimizing these parameters, the process maintains manufacturing precision while reducing material usage.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If continuous printing is used, then productivity is improved, but air pocket structural integrity may be compromised due to insufficient curing

Engineering Contradiction:

Improveprinting speedVSAvoidair pocket enclosure reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Support walls are constructed in advance during the continuous printing process to provide preliminary structural reinforcement. These pre-formed support walls ensure that air pockets maintain their structural integrity even when printing continues without interruption, preventing deformation and ensuring reliable enclosure.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The support walls act as a cushioning structure that protects air pockets from deformation forces during continuous printing. By providing this protective framework beforehand, the system ensures that rapid printing does not compromise the reliability of air pocket enclosure.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 creation of objects with reduced weight and material usage while imparting desired mechanical properties, such as flexibility, by ensuring the structural integrity and complete enclosure of air pockets through enhanced curing and support mechanisms.

Implementation Method 1

the model material is a photopolymer material that is cured with ultraviolet (UV) light after it is jetted

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 2

defining a geometry of the floor to reflect light radiation towards the overhang

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 3

filling air pockets with liquids to prevent oxygen inhibition

Methodology Applied

Scientific EffectOxygen inhibition prevention: Absorption (physical)

Data Source

PatentUS12059847B2Method for additive manufacturing an object

Publication Date: 2024.08.13 STRATASYS LTD

AI summary

An additive manufacturing method for printing an object includes receiving three-dimensional printing data corresponding to the object, defining an internal region of the object to be formed with a structured air pocket and printing the object with an additive manufacturing system. The object includes an internal region formed with a structured air pocket.