Double-Wall 3D Printed Grid Structure for High-Aspect-Ratio X-Ray Absorption
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Solution Overview
Problem
Existing 3D printing technologies struggle to produce high-aspect-ratio three-dimensional structures with small wall thickness and pixel pitch for applications like large area anti-scatter grids, leading to inefficiencies in reducing scattered radiation in medical imaging devices.
Innovation Solution
A method involving the deposition of plastic supporting wall elements and a metal-containing material to form sandwich walls, allowing for the construction of high-aspect-ratio structures with precise control over wall thickness and pixel pitch, using techniques like FDM and SLS for additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If one-dimensional stacking technology is used for large area anti-scatter grids, then the structure can be manufactured with existing technology, but the wall thickness cannot be made small enough and the pixel pitch cannot be reduced sufficiently
Solution Approach 1:
The patent transitions from one-dimensional stacking to two-dimensional grid structures with high aspect ratios. This dimensional change enables smaller wall thickness and pixel pitch while maintaining structural integrity through the grid pattern, resolving the limitation of 1D stacking technology.
Solution Approach 2:
The patent uses composite materials consisting of metal powder (for radiation opacity) mixed with plastic material or binder. This composite approach enables the creation of thin-walled structures with sufficient radiation absorption properties, allowing reduced wall thickness and pixel pitch while maintaining manufacturing feasibility.
2Reliability
If the wall thickness is reduced and pixel pitch is reduced for 2D ASGs, then the radiation transmission properties improve, but the distance between walls becomes shorter making manufacturing more difficult
Solution Approach 1:
By implementing a 2D grid pattern rather than 1D stacking, the design achieves shorter wall distances while maintaining structural stability. The grid configuration distributes mechanical loads across multiple directions, enabling reduced spacing between walls while preserving radiation transmission performance.
Solution Approach 2:
The patent optimizes parameters including wall thickness, pixel pitch, and wall distance to achieve the desired balance between radiation transmission and manufacturing feasibility. By carefully controlling these geometric parameters within specific ranges, the design achieves improved radiation properties while remaining manufacturable.
3Reliability
If high-aspect-ratio three-dimensional structures are printed, then the radiation detection quality improves, but the printing process becomes more challenging
Solution Approach 1:
The high-aspect-ratio structure is divided into successive layers that are printed sequentially. Each layer consists of deposited material forming supporting wall elements and center wall elements. This layer-by-layer segmentation makes the printing of high-aspect-ratio structures manageable and controllable.
Solution Approach 2:
The patent deposits supporting wall elements made of plastic material first to create a stable framework, then fills the confined regions with metal-containing material. This preliminary action of creating the plastic support structure before adding the functional metal material simplifies the printing process for high-aspect-ratio structures.
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 the production of high-quality anti-scatter grids with improved radiation detection parameters, such as reduced scatter radiation-to-primary radiation ratio and enhanced signal-to-noise ratio, through the use of radiation-opaque materials like tungsten and molybdenum.
Implementation Method 1
The metal-containing material is a radiation opaque material... selectively absorbing or transmitting x-ray radiation
Implementation Method 2
depositing a layer of a plastic material on a substrate to form a first supporting wall element
Implementation Method 3
The x-ray absorbing metal powder is built into 3D structures by laser melting
Implementation Method 4
The metal-containing material comprises a mixture of metal powder in a plastic material or a mixture of metal powder in a binder material
Data Source
AI summary
In order to improve three-dimensional (3D) printing a high-aspect-ratio three-dimensional metal structures, there is provided a printing method that builds a wall comprising a center part made out of a metal-containing material and left and right parts made out of a plastic material forming first and second supporting wall elements. The plastic support material may be used to enable the build-up of a high-aspect-ratio 3D structure. The proposed printing strategy may be applicable to a cost-effective 3D printing technology, such as fused deposition molding (FDM).