Ballistics Gel 3D Printing Through Controlled Melting

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Solution Overview

Problem

Conventional molding methods for ballistics gelatin are time-consuming, expensive, and limit the complexity of structures that can be fabricated, preventing its use in applications beyond the ballistics market due to incompatibility with current 3D printing technologies.

Innovation Solution

A system and method for 3D printing ballistics gel and low melting point materials using syringe-based and gear pump-based printheads, enabling the creation of complex structures with fine or large features, respectively, and allowing for digital manufacturing tools to simulate human body parts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional molding methods are used to fabricate ballistics gelatin structures, then manufacturing precision and structural complexity are limited, but the fabrication process is time-consuming and expensive

Engineering Contradiction:

Improvefabrication speedVSAvoidstructural complexity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies parameter changes by controlling the melting temperature of the gelatin material through precise temperature management during 3D printing. The system heats the gelatin to a melting point that allows extrusion through the printhead, then allows it to cool and solidify into the desired complex structure, enabling both high productivity and manufacturing precision

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces conventional mechanical molding methods with a digital 3D printing system that uses computer-controlled extrusion of melted gelatin. This substitution enables complex structures to be fabricated directly from digital models without requiring complex molds or multiple assembly steps, significantly improving both productivity and structural complexity capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If ballistics gelatin is used for medical and optical applications, then flexibility and optical clarity are improved, but compatibility with current 3D printing technologies is lost

Engineering Contradiction:

Improveapplication rangeVSAvoid3D printing compatibility

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent utilizes phase transitions of gelatin by controlling its transition between solid and liquid states. The gelatin is heated to melt into a liquid state for extrusion through the printhead, then cooled to solidify into the final structured form. This phase transition approach enables gelatin to be compatible with 3D printing while maintaining its desirable properties for medical and optical applications

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The patent introduces an intermediary heating system and temperature control mechanism between the gelatin material and the 3D printing process. This intermediary system manages the gelatin's temperature to maintain it in a printable state during extrusion, then allows cooling to achieve the final solid structure, bridging the gap between gelatin's natural properties and 3D printing requirements

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If low melting point materials are printed using heated printheads, then extrusion is enabled, but material properties may deteriorate due to prolonged exposure to high temperatures

Engineering Contradiction:

Improveextrusion capabilityVSAvoidmaterial property retention

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies the skipping principle by rapidly extruding the gelatin material through the heated printhead in a continuous, quick process. The material is heated only briefly during the extrusion moment itself, then immediately deposited and allowed to cool, minimizing the time the material spends at high temperatures and preventing property deterioration while maintaining extrusion capability

Inventive Principle:

Principle #21Skipping (Rushing through)

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

Enables cost-effective and flexible 3D printing of ballistics gel for medical and optical applications, providing unparalleled flexibility, optical clarity, and the ability to create complex structures with fast turnaround times, replacing traditional methods and materials.

Implementation Method 1

heating the ballistics gelatin to a melting point temperature sufficient to melt the ballistics gelatin

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

extruding the melted ballistics gelatin through a printhead

Methodology Applied

Scientific EffectExtrusion: Extrusion

Implementation Method 3

The ballistics gelatin is then extruded through a printhead and allowed to cool and solidify

Methodology Applied

Scientific EffectCooling and solidification: Freezing

Data Source

PatentUS20250282092A13D Printing of Low Melting Point Materials

Publication Date: 2025.09.11 THE BOARD OF TRUSTEES OF THE UNIV OF ARKANSAS

AI summary

A system and method that enables 3D printing of ballistics gel and other low melting point materials.