3D Printing Curing Time Control via Powder Bed Depth
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Solution Overview
Problem
In 3D printing, the curing time of binders can vary with part thickness, making it challenging to determine the optimal curing time, especially when multiple parts are printed together, leading to inconsistencies in the final product.
Innovation Solution
A 3D printing system controller determines the curing time based on the depth of the powder bed, using sensors to measure the build platform position or counting the number of layers applied, and adjusts the curing unit accordingly to ensure accurate curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed curing time is used for all parts, then the curing process is simple to control, but the curing quality varies with part thickness leading to inconsistencies
Solution Approach 1:
The patent changes the curing time parameter based on the powder bed depth parameter. The controller adjusts the curing time dynamically according to the measured or recorded powder bed depth, transforming a fixed parameter into a variable one that adapts to different part thicknesses and configurations.
Solution Approach 2:
The system uses feedback by measuring the actual powder bed depth with sensors or recording the number of layers applied, then using this information to determine the appropriate curing time. This closed-loop approach ensures the curing process adapts to the actual state of the printed parts.
2Reliability
If the curing time is extended to ensure thorough curing of thick parts, then curing completeness is improved, but the curing time for all parts increases reducing productivity
Solution Approach 1:
The curing time parameter is changed from a fixed extended duration to a dynamically adjusted value based on powder bed depth. This allows thin parts to receive minimal curing time while thick parts receive extended curing time, optimizing both reliability and productivity.
Solution Approach 2:
Instead of applying excessive curing time to all parts, the system applies partial curing time to parts that need it less (thin parts) and excessive curing time only to parts that need it more (thick parts). This selective approach improves overall productivity while maintaining reliability where needed.
3Productivity
If the curing time is reduced to increase productivity, then curing throughput is improved, but the curing quality of thick parts deteriorates
Solution Approach 1:
The system changes the curing time parameter from a uniformly reduced value to a selectively adjusted value based on powder bed depth. This allows maintaining high productivity overall while ensuring adequate curing quality for thick parts through extended curing time when needed.
4Measurement precision
If manual determination of curing time is used, then the system is simple to operate, but the curing time accuracy varies leading to inconsistent results
Solution Approach 1:
The system performs self-service by automatically measuring the powder bed depth and determining the appropriate curing time without operator intervention. The controller autonomously adjusts the curing parameters based on the actual state of the printed parts, eliminating manual determination errors.
Solution Approach 2:
The automated system uses feedback from sensors or layer counting to continuously monitor the powder bed depth and adjust the curing time accordingly. This closed-loop control ensures high measurement precision while maintaining ease of operation through automation.
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 method allows for more precise control of the curing process, ensuring consistent part quality by correlating the powder bed depth with the necessary curing time, improving the robustness of 'green parts' and the final sintered metal objects.
Implementation Method 1
The binder is cured to bind the metal powder particles together in the desired shape for further processing
Implementation Method 2
After depowdering, the green part is heated in a sintering furnace to burn off any residual binder and sinter/fuse the metal particles to form the final metal object
Data Source
AI summary
In one example, a memory having instructions thereon that when executed cause a 3D printing system to determine a cure time for a functional agent applied to print a part as a function of build platform position and then cure the functional agent for the determined cure time.