Bio-Composite Additive Manufacturing for Sustainable Large-Scale Production

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Solution Overview

Problem

Current additive manufacturing processes face challenges in sustainability, scalability, and control of geometry and physical properties, particularly with the use of non-compostable thermoplastics and bio-composites that require hazardous solvents and exhibit significant dimensional changes during processing, hindering large-scale and regional modular manufacturing.

Innovation Solution

A bio-composite material comprising a ratio of chitosan to cellulose (1:5 to 1:12) is used, which is free from chemical modification and solvent-based processing, combined with a mobile apparatus for large-scale additive manufacturing that includes a spatial positioning component, material dispenser, and controller for precise control of material deposition, enabling 'on-demand' and region-specific production with minimized environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If bio-composite materials are used for sustainable manufacturing, then environmental sustainability is improved, but dimensional stability deteriorates due to moisture removal during hardening

Engineering Contradiction:

Improveenvironmental sustainabilityVSAvoiddimensional stability

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The patent changes the chemical composition parameters of the bio-composite material by using chitosan (carbohydrate) and collagen (protein) as binding agents instead of traditional water-based binders. This parameter change fundamentally alters the material's behavior during processing, eliminating the problematic moisture removal phase while maintaining sustainability and dimensional stability throughout manufacturing.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite materials consisting of chitosan or collagen bound with cellulose fibers. This composite structure combines the sustainability benefits of natural materials with the dimensional stability required for precision manufacturing, creating a material that is both environmentally friendly and manufacturable at large scales.

Inventive Principle:

Principle #40Composite materials

2Productivity

If large-scale additive manufacturing is implemented, then productivity is improved, but control of geometry and physical properties deteriorates

Engineering Contradiction:

Improvemanufacturing scaleVSAvoidgeometry control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent changes the rheological parameters of the fabrication material by formulating it with chitosan and collagen binders, which provide consistent viscosity and flow characteristics. This enables reliable material deposition and geometry control even at large manufacturing scales, overcoming the typical deterioration of precision that occurs when scaling up additive manufacturing processes.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If conventional thermoplastics are used for high-rate manufacturing, then productivity is improved, but environmental sustainability deteriorates due to non-compostability

Engineering Contradiction:

Improvemanufacturing rateVSAvoidenvironmental sustainability

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent uses composite materials made from chitosan, collagen, and cellulose that maintain manufacturing rates suitable for industrial production while being fully compostable and environmentally sustainable, replacing conventional non-compostable thermoplastics.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the chemical composition of the manufacturing material from synthetic thermoplastics to natural biopolymers, fundamentally altering the material's environmental fate while maintaining processability and manufacturing efficiency through careful formulation of the chitosan-collagen-cellulose system.

Inventive Principle:

Principle #35Parameter changes

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

The bio-composite material allows for environmentally friendly, large-scale additive manufacturing with controlled geometry and mechanical properties similar to synthetic materials, reducing shrinkage and logistical costs while maintaining mechanical strength and stability, facilitating regional and localized production.

Implementation Method 1

A bio-composite material comprising a ratio of about 1:5 to about 1:12 of chitosan to cellulose

Methodology Applied

Scientific EffectHydrogen bonding:

Implementation Method 2

a spatial positioning component; a material dispenser component controllable by the spatial positioning component

Methodology Applied

Scientific EffectPositioning control:

Data Source

PatentUS20240157635A1Apparatus for Large Scale Additive Manufacturing, and A Material for Manufacturing

Publication Date: 2024.05.16 SINGAPORE UNIVERSITY OF TECHNOLOGY AND DESIGN

AI summary

The present invention discloses a system for large scale additive manufacturing, an apparatus for large scale additive manufacturing, and a bio-composite material used for the large scale additive manufacturing. The apparatus and the bio-composite material enable the system to operate in a desired manner. The system is able to facilitate “on demand” manufacturing, is able to provide regional/localised modifications for consumers, is able to minimise transportation/storage costs and also minimises damage to the environment.