Specular Reflective Surfaces via Aligned Flake Substrate in FDM Printing
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Solution Overview
Problem
Fused Deposition Modeling (FDM) 3D printing technology faces challenges in creating specular reflecting elements with high reflectivity, as aluminum flakes incorporated in the printing filament result in low reflectivity and complicate the production of optical elements, limiting the use of 3D printing freedom for optical components in LED luminaires and lighting solutions.
Innovation Solution
A method involving the application of a layer of reflective flakes on a substrate followed by 3D printing, where the flakes are aligned to create a specularly reflecting surface, allowing for the production of reflective and decorative surfaces with a metallic appearance on 3D printed items, which can be used as optical elements or integrated into lighting systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If aluminum flakes are incorporated in the printing filament for FDM 3D printing, then the 3D printed item can have reflective properties, but the reflectivity is low and the production of optical elements becomes complicated
Solution Approach 1:
The patent separates the reflective function from the structural printing function by using two distinct components: a substrate printed by FDM and a separate reflective flake layer applied on top. This segmentation allows each component to be optimized independently - the substrate for structural integrity and the flake layer for high reflectivity, thereby resolving the contradiction between achieving reflectivity and maintaining ease of manufacture for optical elements
Solution Approach 2:
The patent creates a composite structure combining FDM-printed thermoplastic material with metallic or ceramic reflective flakes. This composite approach allows the base material to provide structural properties while the flake layer provides high reflectivity, overcoming the limitation of low reflectivity when aluminum flakes are mixed into the printing filament
2Productivity
If FDM is used for printing complicated 3D objects, then productivity is high and cost is low, but creating specular reflecting surfaces with high reflectivity is difficult
Solution Approach 1:
The patent applies the reflective flake layer to the substrate before or during the FDM printing process, rather than trying to achieve reflectivity through the printing material itself. This preliminary action ensures high reflectivity is built into the structure from the outset, while the FDM process continues to operate at high productivity for creating complicated 3D shapes
Solution Approach 2:
The patent introduces a separate reflective flake layer as an intermediary component between the FDM printing process and the final optical function. This mediator allows the FDM printer to focus on creating complex geometries at high speed while the flake layer independently provides the specular reflective surface, resolving the contradiction between productivity and reflectivity
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 3D printed items with specular reflective surfaces that are both functional and decorative, enhancing the capabilities of FDM technology in producing reflective and optical components for lighting systems with improved reflectivity.
Implementation Method 1
the particles comprise light reflective material... in average the main axes of the particles are configured parallel to a tangential plane to the substrate
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3C
AI summary
A method for 3D printing a 3D item (10), the method comprising providing a filament (320) of 3D printable material (201) and printing during a printing stage said 3D printable material (201) on a substrate (1550), to provide said 3D item (10), wherein the printing stage comprises (a) providing a layer (405) comprising particles (410) on the substrate (1550), wherein the particles (410) have a main axis (Al) having a main axis length (LI), and a minor axis (A2) having a minor axis length (L2), wherein the main axis length (LI) and the minor axis length (L2) have a first aspect ratio of at least 5, wherein in average the main axes (Al) of said particles (410) are configured parallel to a tangential plane (P) to the substrate (1550), wherein said particles (410) comprise light reflective material (411), and (b) printing said 3D printable material (201) on said layer (405) on the substrate (1550) to provide said 3D item (10) comprising said layer (405).