Composite Yarn Attachment for 3D Printing on Complex Surfaces
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Solution Overview
Problem
Current three-dimensional printing systems face challenges in efficiently bonding yarns with heat-moldable and melt-resistant materials to complex surfaces, particularly in maintaining attachment while allowing for detachment and movement without delamination, especially on non-flat or irregular surfaces.
Innovation Solution
A method and system that utilize a nozzle to dispense heat-moldable and melt-resistant materials in specific states, bonding them to attachment regions on a base surface by transitioning from liquid to solid, while maintaining the melt-resistant material as a continuous segment, allowing for selective attachment and detachment, and using an actuating system to move the nozzle along various axes for precise placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If yarn is bonded to complex surfaces using conventional three-dimensional printing systems, then attachment is achieved, but delamination occurs during movement and detachment
Solution Approach 1:
The yarn is constructed as a composite material comprising heat-moldable material and melt-resistant material. The heat-moldable material bonds to the base surface when heated, while the melt-resistant material prevents delamination by maintaining structural integrity during subsequent movement and detachment operations.
2Adaptability or versatility
If release layers are used to enable detachment, then movement is allowed, but manufacturing complexity increases
Solution Approach 1:
The invention extracts and eliminates the release layer component from the manufacturing system. Instead of adding a separate release layer, the melt-resistant material within the yarn itself provides the detachment functionality, simplifying the manufacturing process while maintaining the ability to allow movement and detachment.
3Reliability
If heat-moldable material is used for bonding, then attachment to surfaces is achieved, but control over bonding location becomes difficult
Solution Approach 1:
The yarn structure provides local quality differentiation through its composite composition. The heat-moldable material is positioned to bond at specific locations when heated, while the melt-resistant material remains distributed throughout the yarn to prevent delamination at those same locations, enabling precise control over bonding locations on complex surfaces.
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
Enables reliable bonding of yarns to complex surfaces without delamination, allowing for flexible movement and detachment, simplifying the manufacturing process by reducing the need for release layers and enhancing the structural integrity of printed articles.
Implementation Method 1
The heat moldable material bonds to the first attachment region during a transition of the heat moldable material from the liquid state to a solid state
Data Source
AI summary
A method and system are disclosed. A method of printing onto a base having an upper surface spaced from a lower surface by a base thickness includes dispensing a yarn from a nozzle of a printing system and selectively attaching the yarn to a first attachment region. The step of dispensing the yarn includes dispensing a heat-moldable material and a melt-resistant material. The step of selectively attaching the yarn to the first attachment region includes moving the nozzle into the first attachment region. The step of moving the nozzle into the first attachment region reduces the base thickness by a prodding distance. The heat-moldable material bonds to the first attachment region.