Cryogenic 3D Printing with Immersed Liquid Level Control
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Solution Overview
Problem
Current 3D printing technologies face challenges in producing objects with phase transition temperatures lower than room temperature, particularly in tissue engineering where precise control over microstructure is critical for generating viable biological scaffolds and structures, due to limitations in controlling the freezing process and maintaining consistent temperature gradients.
Innovation Solution
The development of a cryogenic 3D printing system that immerses the printing object in a temperature-controlled liquid, allowing precise control over thermal, composition, and geometrical parameters of the solidification process, ensuring the entire object remains immersed in a controlled liquid environment throughout the printing process, with continuous adjustment of the liquid level to match the printing interface, thereby maintaining consistent freezing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional 3D printing is performed in open air at room temperature, then the printing process is simple and accessible, but the material phase transition temperature must be higher than room temperature, limiting the types of materials that can be used
Solution Approach 1:
The patent introduces a temperature-controlled liquid environment as an intermediary medium between the printed material and the ambient air. This liquid medium acts as a thermal mediator that enables phase transitions of materials with lower transition temperatures (such as frozen materials or materials requiring cryogenic conditions) while isolating the printing process from room temperature conditions. The liquid environment allows photopolymers, thermopolymers, plastics, and metal powders to undergo controlled phase changes during printing.
2Manufacturing precision
If the printing object is not fully immersed in temperature-controlled liquid, then the printing setup is simpler, but the temperature control and freezing process consistency deteriorate
Solution Approach 1:
The patent implements a feedback control system that continuously monitors the liquid level in the temperature-controlled environment and automatically adjusts it to maintain optimal immersion of the printed object. Sensors detect the position of the printed layers, and the system responds by adding or removing liquid to ensure consistent thermal contact. This feedback mechanism ensures that the entire printed object remains at the desired temperature throughout the printing process, maintaining precise temperature control despite the added complexity of the liquid level management system.
3Productivity
If rapid freezing is used to produce frozen materials, then the production speed is faster, but the microstructure control and thermal stress management become more difficult
Solution Approach 1:
The patent employs parameter changes by controlling the temperature of the liquid medium and the rate of material deposition to optimize the freezing process. By adjusting the liquid temperature to specific values and controlling the layer deposition rate, the system achieves rapid freezing while maintaining control over the resulting microstructure. The temperature-controlled liquid environment allows for tuned cooling rates that balance production speed with microstructure quality, preventing excessive thermal stresses that would occur with uncontrolled rapid freezing.
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 the production of complex, biocompatible tissue scaffolds with controlled microstructure and macrostructure, enhancing the viability and functionality of printed biological structures by maintaining consistent temperature and minimizing thermal stresses, thus overcoming limitations of existing methods in tissue engineering and other applications.
Implementation Method 1
The printed object is removed from the temperature controlled liquid or the temperature controlled liquid is removed from around the printed object
Implementation Method 2
the material used in each layer undergoes a phase transformation from a malleable state of matter when it is added to the object to a solid state of matter
Implementation Method 3
maintaining consistent temperature and minimizing thermal stresses
Data Source
AI summary
Systems, apparatus and methods for producing objects with cryogenic 3D printing with controllable micro and macrostructure with potential applications in tissue engineering, drug delivery, and the food industry. The technology can produce complex structures with controlled morphology when the printed 3D object is immersed in a liquid coolant, whose upper surface is maintained at the same level as the highest deposited layer of the object. This ensures that the computer-controlled process of freezing is controlled precisely and already printed frozen layers remain at a constant temperature. The technology controls the temperature, flow rate and volume of the printed fluid emitted by the dispenser that has X-Y positional translation and conditions at the interface between the dispenser and coolant surface. The technology can also control the temperature of the pool of liquid coolant and the vertical position of the printing surface and pool of coolant liquid.