Continuous 3D Printing with Support Fluid Buoyancy
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Solution Overview
Problem
Current 3D printing technologies are inefficient for printing soft materials due to slow print speeds, which are impractical for clinical applications, especially for chronic wounds requiring frequent dressing changes, as they are designed for rigid materials and lack compatibility with soft structures.
Innovation Solution
A system and method utilizing a resin tank, optical image source, and support fluid reservoir to maintain a thin crosslinkable resin layer and employ a support fluid that provides buoyant force, allowing continuous and rapid printing of soft gel materials by modulating light and displacing the support fluid at the same rate as the print height, enabling the printing of complex geometries without collapse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional FDM or SLA 3D printing methods are used for soft materials, then spatial control and resolution are achieved, but print speed is severely limited due to layer-by-layer actuation
Solution Approach 1:
The patent replaces the mechanical layer-by-layer actuation system with an optical projection system that can selectively crosslink resin at any height position without mechanical movement, achieving both high resolution and fast printing speeds simultaneously
Solution Approach 2:
The patent enables continuous printing by maintaining a constant thin layer of photocrosslinkable resin on the build platform and using optical projection to continuously form 3D structures without the need to stop for layer transitions, eliminating idle time between layers
2Strength
If existing 3D printers designed for rigid materials are used, then structural support is maintained, but compatibility with soft gel structures is lost
Solution Approach 1:
The patent changes the material parameter from rigid to soft photocrosslinkable resin, and adjusts the printing parameters including using a constant thin resin layer and optical projection at controlled heights to enable printing of soft gel structures while maintaining structural integrity
Solution Approach 2:
The patent introduces a support fluid as an intermediary medium that provides buoyant support to soft gel structures during printing, replacing the need for mechanical support structures and enabling complex soft material geometries
3Adaptability or versatility
If filament extrusion method similar to FDM is used for soft materials, then soft material printing is enabled, but print speed becomes too slow for clinical applications
Solution Approach 1:
The patent replaces the slow mechanical filament extrusion system with a fast optical projection system that selectively crosslinks resin, achieving both soft material printing capability and high speed suitable for clinical wound dressing applications
Solution Approach 2:
The patent enables continuous printing by maintaining a constant thin layer of photocrosslinkable resin and using optical projection to continuously form 3D structures without mechanical interruptions, dramatically increasing print speed for clinical applications
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 enables faster 3D printing of soft materials, suitable for clinical environments, allowing for quick production of wound dressings with complex geometries and supporting soft gel structures during printing, enhancing print speed and reducing the need for physical support structures.
Implementation Method 1
The optical image source modulates light in accordance with a 3D image to vary a degree and pattern of crosslinking in a photocrosslinkable resin in the resin tank
Implementation Method 2
The support fluid reservoir is in fluid communication with the resin tank and includes a support fluid which is immiscible with the photocrosslinkable resin
Data Source
AI summary
Systems and methods for continuous printing of a three-dimensional (3D) object are provided. The system includes a resin tank, an optical image source, a support fluid reservoir and a pumping structure. The resin tank is where the 3D object is printed and includes a print bed to form a base of the 3D object. The optical image source modulates light in accordance with a 3D image to vary a degree and pattern of crosslinking in a photocrosslinkable resin in the resin tank. The support fluid reservoir is in fluid communication with the resin tank and includes a support fluid which is immiscible with the photocrosslinkable resin. And the pumping structure is configured to transfer the support fluid from the support fluid reservoir to the resin tank such that the support fluid rises in the resin tank at a same rate as vertical height of a top of the 3D object as the 3D object is printed on the print bed.