Electron Beam FDM Curing for Stable Concrete Deposition
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Solution Overview
Problem
Existing additive manufacturing processes for concrete, such as fused deposition modeling (FDM), face challenges in balancing extrudability and printability, leading to post-deposition deformations and mechanical instability due to incomplete curing in air.
Innovation Solution
The use of an electron beam assisted system that generates a particle beam to cure and cross-link concrete extruded materials immediately after deposition, ensuring rapid setting and improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If concrete material is extruded through a nozzle to form layered filamentous structure, then ease of discharge through nozzle is improved, but post-deposition deformations occur due to incomplete curing in air
Solution Approach 1:
The electron beam is applied immediately after material deposition to initiate and accelerate curing before the material can deform under its own weight or subsequent layer loads. This preliminary curing action transforms the material from a deformable state to a stable state, preventing post-deposition deformations while maintaining ease of extrusion
Solution Approach 2:
The electron beam irradiation fundamentally changes the curing parameter of the concrete material by inducing rapid cross-linking and setting reactions. This parameter change accelerates the transition from uncured to cured state, allowing the material to maintain shape and resist deformation while preserving extrudability through optimized material formulation
2Device complexity
If curing of extruded build material takes place in air, then no additional equipment is required, but mechanical properties are insufficient due to incomplete curing
Solution Approach 1:
The natural air curing process is replaced with electron beam irradiation, which uses electromagnetic energy to induce rapid and complete curing. This substitution provides superior mechanical properties through controlled cross-linking while maintaining relatively simple device configuration by integrating the electron beam source with the existing extrusion system
Solution Approach 2:
The electron beam is applied in a periodic manner synchronized with the deposition process, irradiating the material in layers as they are extruded. This periodic irradiation ensures complete curing throughout the build process, achieving superior mechanical properties while maintaining process efficiency
3Device complexity
If conventional FDM process is used for concrete, then process simplicity is maintained, but mechanical instability occurs due to incomplete curing
Solution Approach 1:
The electron beam curing system is merged with the conventional FDM extrusion process, combining the deposition and curing operations into a unified manufacturing system. This integration maintains process simplicity by using a single pass where material is extruded and immediately cured, while achieving reliable mechanical stability through complete electron beam-induced curing
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 allows for rapid electron beam assisted fused deposition modeling, reducing post-deposition deformations and enhancing the mechanical stability and durability of the concrete structures by ensuring complete curing and cross-linking.
Implementation Method 1
a particle source configured to generate a particle beam, a beam extraction assembly, the beam extraction assembly configured to direct the terminal position of the particle beam on a material deposited by a nozzle
Implementation Method 2
curing and cross-linking concrete extruded materials immediately after deposition
Data Source
AI summary
Methods and systems for electron beam assisted fused deposition modeling can include a particle accelerator configured to generate a particle beam, a shield cone and a magnet configured to direct the particle beam in the shield cone forming a beam extraction assembly configured to direct the terminal position of the particle beam on filament deposited by an additive manufacturing system, and a control system for controlling the beam spot location of the particle beam on the filament, such that the particle accelerator delivers a dose of irradiation along the build path according to the assigned irradiation value with the particle beam.