Circular Printing With Radial Frequency Control for Uniform Deposition

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Solution Overview

Problem

Existing additive manufacturing processes face challenges in achieving uniform coverage and efficient material deposition in circular patterns due to the use of multiple additive sources operating at a single frequency, leading to suboptimal layer formation and coverage uniformity.

Innovation Solution

A system and method where additive sources are distributed across a printing zone and actuated at frequencies proportional to their distance from the center of rotation, allowing for discrete amounts of material to be deposited on a substrate as it rotates, ensuring uniform coverage and enabling the formation of patterns with both material and open spaces within a circular printing area.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple additive sources operate at a single frequency in parallel, then fabrication speed is improved, but coverage uniformity deteriorates

Engineering Contradiction:

Improvefabrication speedVSAvoidcoverage uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Each additive source is assigned a unique actuation frequency based on its radial distance from the center of rotation, creating local differentiation in operating parameters. This ensures that sources at different positions deposit material at rates proportional to their distance, achieving uniform coverage across the entire circular substrate area while maintaining parallel operation of all sources

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The actuation frequency parameter is varied across different additive sources according to their radial position. Sources farther from the center operate at higher frequencies, while those closer to the center operate at lower frequencies. This parameter differentiation resolves the contradiction by enabling each source to contribute appropriately to uniform coverage while all sources operate simultaneously for high productivity

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If additive sources are distributed across a printing zone and actuated at different frequencies, then coverage uniformity is improved, but device complexity increases

Engineering Contradiction:

Improvecoverage uniformityVSAvoidactuation control complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The printing zone is segmented into multiple radial positions, with each position assigned a specific actuation frequency. This segmentation approach simplifies the control strategy by creating a systematic pattern (frequency proportional to radial distance) rather than requiring individualized control for each source, thereby managing device complexity while achieving uniform coverage

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each additive source operates with a periodic actuation signal at its designated frequency. This periodic action, synchronized with the rotational motion of the substrate, ensures that material is deposited at consistent intervals corresponding to the substrate's rotation, achieving uniform coverage through rhythmic, predictable deposition patterns

Inventive Principle:

Principle #19Periodic action

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 provides improved coverage uniformity and allows for the creation of complex geometries with enhanced precision and efficiency in additive material deposition, compared to operating all sources at a single frequency.

Implementation Method 1

additive manufacturing machines may have multiple additive sources, such as material jetting heads

Methodology Applied

Scientific EffectMaterial jetting:

Implementation Method 2

laser polymerization

Methodology Applied

Scientific EffectPhotonic polymerization: Photopolymerisation

Implementation Method 3

The substrate and the additive sources are rotated with respect to each other around a center of rotation

Methodology Applied

Scientific EffectRotational motion:

Data Source

PatentUS11865773B2Additive process for circular printing of electronic devices

Publication Date: 2024.01.09 TEXAS INSTRUMENTS INC

AI summary

A layer of additive material is formed in a circular printing area on a substrate using additive sources distributed across a printing zone. The additive sources form predetermined discrete amounts of the additive material. The substrate and the additive sources are rotated with respect to each other around a center of rotation, so that a pattern of the additive material is formed in a circular printing area on the substrate. Each additive source receives actuation waveforms at an actuation frequency that is proportional to a distance of the additive source from the center of rotation. The actuation waveforms include formation signals, with a maximum of one formation signal in each cycle of the actuation frequency. The formation signals result in the additive sources forming the predetermined discrete amounts of the additive material on the substrate.