Additive Manufacturing Supplementary Structures for Thermal Homogenization
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Solution Overview
Problem
Current 3D printing methods, such as FDM and FFF, face challenges in achieving consistent temperature distribution and process stability, leading to issues like warpage and mechanical property variations in components, particularly in medical and high-performance plastics.
Innovation Solution
Incorporating functional supplementary structures that analyze and adapt temperature management during the printing process by modifying the component geometry or adding separate geometrical bodies, which can be made of different materials, to ensure homogeneous temperature distribution and consistent extrusion rates, thereby enhancing mechanical properties and surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive manufacturing methods are used without supplementary structures, then the manufacturing process is simpler, but the temperature distribution becomes inhomogeneous leading to warpage and reduced manufacturing precision
Solution Approach 1:
The component is divided into functional regions by introducing supplementary structures at specific locations. These structures segment the temperature management function, allowing different regions to be controlled independently for homogeneous temperature distribution during additive manufacturing
Solution Approach 2:
The supplementary structures are designed and integrated into the component geometry before the actual additive manufacturing process begins. This preliminary action ensures that temperature management capabilities are built into the component design, preventing warpage and inhomogeneous temperature distribution during production
2Manufacturing precision
If the component geometry is modified to improve temperature distribution, then manufacturing accuracy improves, but the component design becomes more complex
Solution Approach 1:
Supplementary structures are added only at specific local positions within the component geometry where temperature management is needed, rather than uniformly modifying the entire component. This allows temperature distribution uniformity to be improved while minimizing the impact on overall component shape and function
3Reliability
If extrusion rate is not kept constant, then the printing process is faster, but temperature management becomes unstable leading to reduced reliability
Solution Approach 1:
The supplementary structures provide a geometric basis for feedback control of the extrusion process. By designing structures that account for varying cross-sectional areas, the system can adjust extrusion rates in real-time to maintain constant material flow and temperature management, ensuring process stability while allowing for optimized printing speeds
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 improves the manufacturing accuracy and dimensional stability of components by homogenizing temperature and maintaining consistent extrusion, resulting in improved mechanical properties and reduced distortion, especially in semi-crystalline plastics used for medical implants and other applications.
Implementation Method 1
the component is analyzed regarding its structure and/or its production parameters in respect of the temperature in the component during production
Implementation Method 2
a supplementary structure is added to the component at those places where the analysis reveals that the structure and/or the production parameters would result in an inhomogeneous temperature distribution during production
Implementation Method 3
a production plan for the component is generated from digital data; the component is analyzed regarding its structure and/or its production parameters in respect of the temperature in the component during production
Implementation Method 4
additive production method; Fused Deposition Modeling; Fused Layer Modeling; Fused Filament Fabrication
Data Source
AI summary
The present invention relates to a method of producing a component by means of an additive production method, including at least the following steps: —a production plan for the component is generated from digital data; —the component is analyzed regarding its structure and/or its production parameters in respect of the temperature in the component during production; and —a supplementary structure is added to the component at those places where the analysis reveals that the structure and/or the production parameters would result in an inhomogeneous temperature distribution during production. The present invention further relates to a component produced by means of an additive production method.