Additive Manufacturing Thermal Control During Component Embedding
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Solution Overview
Problem
Current additive manufacturing systems face challenges in resuming printing after a substantial pause, especially when embedding components within a 3D printed object, which limits the variety of materials and objects that can be created and affects print quality due to issues like part curl and overheating.
Innovation Solution
The system employs a controller to manage the additive manufacturing process by pausing and resuming printing, using a heat source to maintain the build material within a specific temperature range, and employing a placement device to embed components, ensuring good adhesion between layers and mechanical protection of the embedded components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If printing is paused to embed components, then component integration capability is improved, but print quality and dimensional accuracy deteriorate due to part curl and overheating
Solution Approach 1:
The system performs preliminary actions before pausing to embed components: it pre-heats the build chamber to a target temperature, positions the build platform at a specific height, and prepares the material distribution system. These preliminary actions ensure that when printing resumes, the thermal and mechanical conditions are already optimized, preventing part curl and maintaining dimensional accuracy despite the interruption.
Solution Approach 2:
The system employs feedback mechanisms to monitor and adjust printing parameters after resuming from a pause. Sensors detect temperature variations, platform position, and material deposition quality in real-time. The controller uses this feedback to dynamically adjust heating power, platform height, and print speed, compensating for any deviations caused by the pause and ensuring consistent print quality.
2Adaptability or versatility
If printing is resumed after a substantial pause, then component embedding is enabled, but overheating occurs affecting print quality
Solution Approach 1:
Before resuming printing, the system performs preliminary thermal conditioning by maintaining the build chamber at a controlled temperature during the pause. The heating system continues operation at a reduced level to prevent excessive cooling, and when printing resumes, the temperature is already within the optimal range, avoiding sudden thermal shocks that would cause overheating and print defects.
Solution Approach 2:
The system uses periodic thermal cycling during pauses, alternating between heating phases and cooling phases to maintain the build material within a specific temperature window. This periodic action prevents both overheating and excessive cooling, ensuring that when printing resumes, the thermal conditions are stable and suitable for high-quality deposition.
3Adaptability or versatility
If the build platform height is adjusted after a pause, then component placement space is created, but layer adhesion may be compromised
Solution Approach 1:
Before adjusting the build platform height to create space for component placement, the system performs preliminary bonding by depositing a thin layer of material or applying heat treatment to the existing layers. This preliminary action ensures strong inter-layer adhesion is established before the platform is moved, so that when height adjustment occurs, previously deposited layers remain firmly attached and layer strength is maintained.
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 allows for the creation of a wide variety of multi-functional parts with enhanced security and improved print quality by enabling the embedding of components within 3D printed objects, maintaining dimensional accuracy, and ensuring the embedded components are securely integrated without damaging the printed part.
Implementation Method 1
turn on a heat source to maintain fused portions of a partially-printed 3D printed object between a solidification temperature and a melting temperature
Data Source
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AI summary
In one example in accordance with the present disclosure, an additive manufacturing system is described. The additive manufacturing system includes a build material distributor to deposit layers of powdered build material onto a bed to form a three-dimensional (3D) printed object. The additive manufacturing system also includes a controller to interrupt printing of the 3D printed object and to resume printing of the 3D printed object. The additive manufacturing system also includes a heat source to, during an interruption in printing, maintain a temperature of a top surface of the powdered build material between a solidification temperature and a melting temperature for the build material.