Additive Manufacturing Method for Multi-Material 3D Printing
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Solution Overview
Problem
Current additive manufacturing techniques face challenges in achieving desired properties at specific regions within a 3D-printed object, as they often require the removal of unbound powder, which can lead to inefficiencies and limitations in creating objects with varied properties across different regions.
Innovation Solution
The method involves smoothing deposited granular construction material to a uniform thickness before binding, using a combination of deposition and binding units with suction for unbound material removal, and selective binding with a liquid binder, allowing for the creation of objects with regions of different properties by alternating between two or more granular materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If unbound powder is removed after binding process, then manufacturing precision is improved, but productivity deteriorates due to additional removal steps and time consumption
Solution Approach 1:
The patent performs the removal of unbound powder immediately after each layer is deposited and bound, rather than waiting until the end of the manufacturing process. This preliminary action prevents powder accumulation and maintains precise boundaries between regions throughout the build process, while the continuous operation minimizes impact on overall productivity
Solution Approach 2:
The patent extracts unbound powder from the build region using suction means immediately after the binding process for each layer. This extraction occurs layer-by-layer during the manufacturing process rather than as a separate post-processing step, maintaining precision while integrating the removal operation into the main manufacturing flow
2Adaptability or versatility
If multiple granular materials are used to create regions of different properties, then adaptability is improved, but device complexity increases due to multiple deposition units and material management systems
Solution Approach 1:
The deposition unit is designed with multi-functionality to handle multiple granular materials. The same deposition unit can switch between different materials (e.g., soluble and insoluble powders) to create regions with different properties, eliminating the need for separate specialized deposition units for each material type
Solution Approach 2:
The patent applies different granular materials to specific local regions of the build plate based on the desired final properties. For example, soluble material is deposited in regions intended for removal, while insoluble material is deposited in regions to be retained, achieving local property variation without requiring different deposition units for each location
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 production of 3D objects with regions of varying properties, such as different colors, physical properties, or chemical properties, by effectively binding and removing unbound material, enhancing the competitiveness of additive manufacturing processes.
Implementation Method 1
removing unbound granular construction material from the layer comprises applying suction to the layer
Implementation Method 2
a liquid binder may be jetted from the print head onto the build material using a technique similar to ink-jet printing. Such a binder may be an adhesive which solidifies or cures, thereby to bind the granules of the build material together
Implementation Method 3
radiation may be selectively applied to portions of each layer to locally sinter or melt regions of the layer, thereby binding such regions together, for example by the application of a suitably high-intensity laser beam or focussed infrared radiation
Implementation Method 4
radiation may be selectively applied to portions of each layer to locally sinter or melt regions of the layer
Data Source
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AI summary
According to a first aspect of the present disclosure, there is provided an additive manufacturing method. In the method, regions of successively-deposited layers of granular construction material are bound together so as to form a three-dimensional structure of bound material extending through and between the layers. The method comprises depositing a first granular construction material as a layer into a build region. The method comprises selectively binding regions of the first granular construction material together to form bound regions within the layer. The method comprises removing unbound granular construction material from the layer so as to provide at least one void in the layer. The method comprises depositing a second granular construction material into the build region so as to fill the at least one void. The method comprises selectively binding regions of the second granular construction material together to form bound regions within the layer. In the method, the second granular construction material is different from the first granular construction material. The method is repeated to form the object. An apparatus suitable for implementing the method is also disclosed.