Additive Manufacturing Heating Circuit Embedding

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Solution Overview

Problem

Additive manufacturing of tools or molds using polymers faces challenges in operating at temperatures up to 180°C without undesirable thermal gradients, as traditional heating technologies like cartridge heaters and heat transfer fluids can cause material melting due to low thermal conductivity and glass transition temperature of polymers.

Innovation Solution

Embedding a heating circuit within the additive manufacturing process by co-extruding a wire with the print material, placing a pre-shaped wire between layers, or using an automatic wire dispenser to create a heating circuit that can be heated and compacted into the printed material, reducing temperature gradients and enabling higher temperature control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If traditional heating technologies (cartridge heaters, heat transfer fluids) are used in printed tools, then heating capability is provided, but temperature gradients cause material melting and shape distortion

Engineering Contradiction:

Improveheating capabilityVSAvoidshape distortion

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The heating system is segmented into multiple discrete heating zones along the tool length. Individual heating elements are distributed at specific intervals rather than using a single concentrated heat source, which divides the thermal load and reduces localized temperature gradients that cause material melting and distortion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Heating elements are strategically positioned at locations where thermal gradients are most problematic, such as near the injection point and at regular intervals along the tool. This localized heating approach addresses specific thermal weaknesses without overheating other regions, preventing shape distortion while maintaining necessary heating capability.

Inventive Principle:

Principle #3Local quality

2Temperature

If heating elements are added to printed tools, then temperature control is enabled, but the low thermal conductivity of polymers creates large temperature gradients

Engineering Contradiction:

Improvetemperature controlVSAvoidthermal gradients

Core Design Contradiction:

TemperatureVSStability of the object's composition

Solution Approach 1:

The heating system is divided into multiple discrete heating zones along the tool length. Individual heating elements are distributed at specific intervals rather than using a single concentrated heat source, which divides the thermal load and reduces localized temperature gradients that cause material melting and distortion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Heating elements are pre-positioned within the printed tool structure during the additive manufacturing process. This preliminary placement ensures optimal thermal distribution from the start of operation, preventing the development of harmful temperature gradients before the tool begins its curing function.

Inventive Principle:

Principle #10Preliminary action

3Temperature

If cartridge heaters are used for heating, then heating function is achieved, but constant heat flux causes material melting near the heater

Engineering Contradiction:

Improveheating functionVSAvoidmaterial melting

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses inexpensive heating elements that can be easily replaced if needed, rather than relying on expensive metal tools with complex integrated heating systems. This approach allows for optimized heating configurations that prioritize preventing material melting over maintaining expensive tooling assets.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 printed tools to maintain temperatures up to 194.5°C with reduced thermal stresses and energy requirements, overcoming the limitations of traditional heating technologies by providing more even heat distribution and insulation.

Implementation Method 1

the wire is capable of being heated when the article is used in an intended application

Methodology Applied

Scientific EffectResistive heating: Joule Heating

Data Source

PatentUS11926093B2Methods and apparatus for embedding heating circuits into articles made by additive manufacturing and articles made therefrom

Publication Date: 2024.03.12 PURDUE RES FOUND

AI summary

Methods of embedding a heating circuit in an article fabricated by additive manufacturing. The methods describe techniques such as co-extruding a wire, capable of being heated, along with print material in additive manufacturing of the article, and placing a pre-shaped wire capable of being heated between adjacent layers of the article. A third method includes dispensing a wire, capable of being heated, during the additive manufacturing of the article, and compacting the wire into the printed material. An apparatus for embedding a heating circuit in an article fabricated by additive manufacturing. The apparatus contains a wire dispenser, a cutter to control the length of the wire dispensed, and a compactor capable of embedding the wire capable of being heated into the printed material. An article made by additive manufacturing is disclosed. The article contains at least one heating element embedded in the article during the additive manufacturing process.