3D Printer Build Unit Lateral Heaters Thermal Uniformity

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Solution Overview

Problem

Thermal uniformity and controlled temperatures during the preheat, printing, and cooling processes are crucial for ensuring the quality of 3D printed objects, but existing systems face challenges in maintaining uniformity, leading to issues like internal stresses, deformation, and delayed availability due to rapid or slow cooling rates.

Innovation Solution

The build unit incorporates lateral and feedtray heaters with electrical etched resistances that deliver variable power density to maintain uniform temperature profiles, compensating for thermal dissimilarities and reducing hot spots, ensuring consistent heating and cooling across the build chamber.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional heating systems are used in the build unit, then the heating function is provided, but thermal uniformity deteriorates leading to hot spots and temperature variations

Engineering Contradiction:

Improvethermal uniformityVSAvoiddimensional accuracy

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The heating system is segmented into multiple independent heating zones (lateral heaters on sidewalls and feedtray heaters on material storage trays). Each zone can be independently controlled to deliver heat uniformly across different regions of the build chamber, eliminating hot spots and temperature variations that would occur with a single conventional heater.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the build unit are equipped with heating elements tailored to their specific thermal requirements. The lateral heaters address thermal uniformity along the sidewalls, while feedtray heaters specifically address the material storage areas. This localized heating approach ensures each region maintains the appropriate temperature for its function, preventing thermal defects.

Inventive Principle:

Principle #3Local quality

2Productivity

If rapid cooling is applied after printing, then the objects are available for use sooner, but internal stresses and deformation occur

Engineering Contradiction:

Improveavailability timeVSAvoidinternal stresses

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The system performs preliminary uniform heating of the entire build chamber and build material before the printing process begins. This pre-conditioning ensures that thermal gradients are minimized from the start, preventing internal stresses from developing during subsequent cooling. The uniform temperature distribution is maintained throughout the build process, allowing for controlled cooling rates that avoid deformation while still enabling timely object availability.

Inventive Principle:

Principle #10Preliminary action

3Temperature

If conventional heating elements are used, then the device structure is simple, but thermal uniformity deteriorates causing hot spots

Engineering Contradiction:

Improvetemperature uniformityVSAvoidheating system structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

Rather than using one large conventional heater, the system divides the heating function into multiple smaller heating elements positioned at strategic locations (sidewalls and feedtrays). This segmentation achieves superior thermal uniformity by distributing heat sources throughout the build chamber, eliminating the hot spots that would occur with a single centralized heater.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heating elements serve multiple functions: lateral heaters on the sidewalls provide ambient heating and thermal uniformity throughout the build chamber, while feedtray heaters specifically maintain material temperature in the storage trays. This multi-functional approach achieves comprehensive thermal control without requiring overly complex specialized systems for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 ensures high-quality 3D printed objects with improved dimensional accuracy and interlayer strength by maintaining uniform temperature profiles, reducing thermal defects and making the objects available for use sooner.

Implementation Method 1

lateral and feedtray heaters with electrical etched resistances that deliver variable power density

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

maintain uniform temperature profiles, compensating for thermal dissimilarities

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

ensuring consistent heating and cooling across the build chamber

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentUS12053929B2Build units for three-dimensional printers

Publication Date: 2024.08.06 PERIDOT PRINT LLC

AI summary

A build unit for a three-dimensional printer, comprising a housing comprising sidewalls and a build platform movable within the housing. The housing and the build platform form a build chamber. The build unit further comprises a lateral heater mounted on the housing. The lateral heater is operable to apply a uniform housing temperature across all the section of the build unit by delivering variable power density along the housing.