3D Printing Build Material Extraction for Binder Curing
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Solution Overview
Problem
Existing three-dimensional printing systems face challenges in efficiently curing thermally curable binder agents due to the low thermal conductivity of build materials, leading to prolonged curing and cooling times, as well as issues with solvent migration causing agglomeration of build material.
Innovation Solution
The implementation of a 3D printing apparatus and method that involves a partial build material removal operation followed by heating to cure the binder, utilizing a build material extraction module such as a vibration element, blowing device, or vacuum generator to efficiently remove uncured build material and reduce the amount of material to be heated, thereby accelerating the curing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If build material is heated to cure thermally curable binder agent, then binder curing is achieved, but curing time is prolonged due to low thermal conductivity of build material
Solution Approach 1:
The patent extracts removes a portion of the build material from the container before heating, reducing the total amount of material that needs to be heated for binder curing. This extraction step separates the build material into two portions: one removed and one remaining for curing, directly addressing the time-consuming heating process caused by low thermal conductivity.
2Reliability
If build material is heated to cure binder agent, then binder curing is achieved, but cooling time is prolonged after curing
Solution Approach 1:
By removing a portion of the build material before heating, the patent reduces the thermal mass that must be cooled after curing. This extraction principle applies to both the heating and cooling phases, significantly reducing the time required for the complete thermal cycle while ensuring proper binder curing of the remaining material.
3Reliability
If build material is heated to cure binder agent, then binder curing is achieved, but energy consumption increases
Solution Approach 1:
The patent removes a portion of the build material before heating, reducing the total mass that requires thermal energy for binder curing. This extraction principle directly reduces energy consumption by minimizing the volume of material subjected to heating, while still achieving complete curing of the remaining material containing the binder agent.
4Reliability
If build material is heated to cure binder agent, then binder curing is achieved, but solvent migration causes agglomeration of build material
Solution Approach 1:
By removing a portion of the build material before heating, the patent reduces the total amount of material present during the curing process. This extraction principle minimizes the potential for solvent migration and agglomeration by reducing the overall volume of build material that could be affected by these harmful effects during heating.
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 significantly reduces the time required for curing and cooling of green parts, from up to 16 hours and 10 hours to less than 2 hours and 1 hour respectively, while also improving build material recyclability and energy efficiency by minimizing solvent contamination and energy consumption.
Implementation Method 1
utilizing a build material extraction module such as a vibration element
Implementation Method 2
utilizing a build material extraction module such as a vibration element, blowing device
Implementation Method 3
utilizing a build material extraction module such as a vibration element, blowing device, or vacuum generator
Implementation Method 4
heating the remaining build material to a temperature sufficient to thermally cure the binder agent
Implementation Method 5
heating the remaining build material to a temperature sufficient to thermally cure the binder agent
Data Source
AI summary
A 3D printing apparatus is disclosed herein. The apparatus comprises a container, a build material extraction module, an energy source and a controller. The container is to receive a build volume comprising portions in which an un-cured thermally curable binder has been applied to define a 3D object to be generated and portions on which no binder has been applied. The build material extraction module is to remove part of the build material on which no binder has been applied. The energy source to heat the contents of the container. And the controller is to control the build material extraction module to remove part of the build material on which no binder has been applied; and control the energy source to heat the build material to thermally cure any binder in the container.