3D Printing Binding Agent Temperature Control for Viscosity Management
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Solution Overview
Problem
Three-dimensional printing systems face challenges in precisely and reliably dispensing binding agents, especially those with dissolved solids, due to their viscosity and reactivity, which affects the precision of the cross-section formation in printed articles.
Innovation Solution
A system utilizing a drop-on-demand piezoelectric printhead with controlled temperature binding agents and specific voltage waveforms to selectively jet binding agents onto powder layers, maintaining the binding agent temperature between 25 to 40 degrees Celsius and using unique voltage pulse combinations to manage drop ejection, ensuring reliable and precise binding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If binding agents with dissolved solids are used, then the binding capability is improved, but the dispensing precision and reliability deteriorate due to viscosity and reactivity issues
Solution Approach 1:
The patent applies parameter changes by precisely controlling the temperature of the binding agent (maintaining it between 20-40°C) and adjusting the viscosity through temperature control. This allows the binding agent with dissolved solids to maintain optimal flow characteristics for precise dispensing while retaining its binding capabilities. The waveform parameters (voltage, pulse duration) are also adjusted to match the modified viscosity conditions.
Solution Approach 2:
The system dynamically adjusts the dispensing parameters based on the binding agent's temperature and viscosity conditions. The piezoelectric printhead uses dynamically controlled voltage waveforms that adapt to the fluid's state, allowing real-time optimization of drop ejection for binding agents with dissolved solids, thereby maintaining both reliability and precision.
2Reliability
If standard dispensing methods are used, then the process is simple, but the drop ejection stability deteriorates due to viscosity variations
Solution Approach 1:
The system performs preliminary action by pre-heating or cooling the binding agent to the optimal temperature range (20-40°C) before dispensing. This preliminary temperature adjustment ensures the binding agent has the correct viscosity for stable drop ejection, preventing viscosity-related dispensing issues before they occur during the actual printing process.
Solution Approach 2:
The patent implements feedback control through temperature sensors that continuously monitor the binding agent temperature and adjust the heating/cooling elements accordingly. This closed-loop feedback system maintains the binding agent within the optimal temperature range, ensuring consistent viscosity and stable drop ejection while automatically compensating for environmental variations.
3Strength
If higher viscosity binding agents are used, then the binding strength is improved, but the dispensing precision deteriorates
Solution Approach 1:
The patent resolves this contradiction by changing the temperature parameter of the binding agent to optimize its viscosity. By maintaining the temperature between 20-40°C, the system achieves a viscosity range that provides both adequate binding strength and dispensing precision. The higher viscosity binding agents are temperature-adjusted to flow at optimal rates for precise cross-section formation while retaining their binding capabilities.
Solution Approach 2:
The system uses periodic voltage waveforms (pulsed signals) to eject drops of high-viscosity binding agent. The periodic nature of these waveforms allows controlled build-up and release of pressure, enabling precise drop ejection even from high-viscosity materials. This periodic actuation ensures that each drop is ejected with consistent force and placement accuracy.
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 reliability and precision of binding agent dispensing, optimizing the operating conditions for stable drop ejection and preventing nozzle clogging, thereby improving the fabrication of three-dimensional articles with precise cross-sectional control.
Implementation Method 1
The printhead is a drop-on-demand fluid-jetting piezoelectric printhead configured to receive the binding agent from the fluid supply
Implementation Method 2
The controller is configured to (a) operate the fluid supply and/or the printhead to elevate a temperature of the binding agent to above 25 degrees Celsius
Data Source
AI summary
A system for fabricating a three-dimensional article includes a fluid supply with binding agent, a printhead, a powder dispenser, and a controller. The fluid supply is for containing a binding agent. The controller is configured to (a) operate the fluid supply and/or the printhead to elevate a temperature of the binding agent to above 25 degrees Celsius, (b) operate the dispenser to dispose a layer of the powder at a build plane, (c) scan and operate the printhead to selectively jet the binding agent onto the layer of powder to bind a layer of the three-dimensional article, and (d) repeat operating the dispenser and scanning and operating the printhead to complete fabrication of the article. Jetting or not jetting the binding agent includes individually operating drop ejectors of the printhead using a voltage waveform. The waveform can include one or more of a non-ejecting pulse and an ejecting pulse.