Additive Manufacturing Base Thermal Homogeneity Control
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Solution Overview
Problem
Additive manufacturing systems face issues with geometrical accuracy and mechanical properties due to temperature differentials between layers, leading to curling and warping, which can result in malfunction and increased build material waste.
Innovation Solution
A base with a minimum temperature and thermal uniformity is established by measuring thermal profiles and using feedback loops to modify the deposition of printing agents, such as fusing and detailing agents, to control heating and cooling across the base layers, reducing temperature variations and optimizing the build process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a base is formed from layers of build material at ambient temperature, then the base can be quickly prepared, but temperature differentials between layers cause curling and warping of the object
Solution Approach 1:
The base layers are pre-heated to a controlled temperature before the object is built upon them. This preliminary thermal preparation eliminates temperature differentials that would otherwise cause curling and warping, while the base can still be formed quickly by laying down material layers and applying heat uniformly across the base area.
2Manufacturing precision
If zoned heating elements are used to heat each base layer differentially, then temperature uniformity can be achieved, but the number of sacrificial layers increases
Solution Approach 1:
Printing agents are selectively applied to different zones of the base layers based on local temperature requirements. The system measures the thermal profile and determines a pattern of application for printing agents, applying them preferentially to areas that need additional heating or cooling to achieve the desired minimum temperature and thermal homogeneity, thereby reducing the need for excessive sacrificial layers.
3Manufacturing precision
If printing agents are selectively deposited to control heating, then thermal homogeneity is improved, but the process complexity increases
Solution Approach 1:
The system measures the thermal profile of the base layers and uses this feedback information to dynamically determine the pattern of application for printing agents. The controller adjusts the deposition of printing agents based on real-time thermal measurements, applying them selectively to areas that need temperature adjustment. This closed-loop feedback control achieves thermal homogeneity while automating the complex decision-making process.
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 enhances the build quality of 3D objects by reducing curling and warping, achieving superior mechanical properties and minimizing the number of sacrificial layers, thus reducing material waste and improving the efficiency of the additive manufacturing process.
Implementation Method 1
a radiation source (120) to heat the base of build material
Implementation Method 2
a thermal sensor (130) to measure a thermal profile of the base
Implementation Method 3
the printing agents may comprise a fusing agent and a detailing agent... the fusing agent is selectively applied to a layer in areas where particles of the build material are to fuse together
Data Source
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AI summary
Certain examples described herein relate to preparing a base of build material for additive manufacturing. The base is formed from layers of build material that do not form part of an object undergoing additive manufacture. The base is heated by the application of energy, for example using a radiation source. A thermal profile of the base is measured after heating and is used to determine a pattern of application of at least one printing agent to the base. The pattern of application is used to deposit the at least one printing agent upon the base, wherein the presence of the printing agent affects the heating of the base. In this way the pattern of application of printing agent may be used to effect a thermal homogeneity of the base.