Embedded Heater Element for 3D Printed Injection Mold Weld Line Prevention
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Solution Overview
Problem
The existing methods for manufacturing three-dimensional shaped objects using selective laser sintering often result in weld lines during resin molding, which are undesirable due to poor resin joining and air entrapment, leading to complex mold configurations and ineffective temperature control.
Innovation Solution
A method involving the repeated formation of solidified layers with a heater element embedded within the three-dimensional shaped object, allowing localized heat control and venting, thereby preventing weld lines by situating the heater element near potential weld regions and incorporating a porous solidified portion for degassing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a metal mold is designed with multiple gates or complex cavity shapes, then productivity is improved by enabling simultaneous injection into multiple cavities, but weld lines occur due to air entrapment and poor resin joining
Solution Approach 1:
The heater element is pre-installed within the three-dimensional shaped object during its manufacturing process via selective laser sintering. This preliminary action ensures that the heating capability is already in place before the injection molding process begins, allowing immediate temperature control when resin flows converge, preventing weld line formation from the outset
Solution Approach 2:
The invention changes the temperature parameter locally at the weld line region by incorporating a heater element that can independently control temperature at the resin convergence point. This localized parameter change prevents the resin from cooling too quickly, maintaining its joining capability and eliminating weld lines while allowing the rest of the mold to operate at optimal cooling temperatures
2Reliability
If a pin or steam circuit is added to the metal mold to prevent weld lines, then resin joining quality is improved, but device complexity increases due to additional components
Solution Approach 1:
The invention merges the temperature control function directly into the three-dimensional shaped object itself by embedding a heater element during its manufacturing process. This eliminates the need for separate pins or steam circuits, as the object's own structure provides the necessary heating capability, thereby reducing device complexity while maintaining weld line prevention
Solution Approach 2:
The three-dimensional shaped object serves its own temperature control needs by having a heater element integrated within it. This self-service approach eliminates the need for external temperature control mechanisms, simplifying the overall mold configuration while effectively preventing weld lines through localized heating
3Ease of manufacture
If traditional temperature control methods are used in metal molds, then manufacturing simplicity is maintained, but temperature control efficiency is poor due to inadequate localized heating
Solution Approach 1:
The invention applies local quality by providing temperature control only where needed - at the weld line region where resin flows converge. The heater element is strategically positioned within the three-dimensional shaped object to provide localized heating, while the rest of the mold maintains its simple manufacturing design without additional temperature control components
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 effectively prevents weld lines by providing localized temperature control and venting, simplifying mold design and improving temperature control efficiency, while maintaining high heat conductivity and responsiveness.
Implementation Method 1
forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing sintering of the powder in the predetermined portion or melting and subsequent solidification thereof
Implementation Method 2
irradiating a predetermined portion of a powder layer with a light beam
Implementation Method 3
a heater element is disposed on the solidified layer during the repeated steps (i) and (ii), and thereby the heater element is situated within the three-dimensional shaped object
Implementation Method 4
providing localized temperature control and venting, simplifying mold design and improving temperature control efficiency
Data Source
AI summary
There is provided a method for manufacturing a three-dimensional shaped object, the method comprising the repeated steps of: (i) forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing a sintering of the powder in the predetermined portion or a melting and subsequent solidification thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, followed by the irradiation of a predetermined portion of the powder layer with the light beam, wherein a heater element is disposed on the solidified layer during the repeated steps (i) and (ii), and thereby the heater element is situated within the three-dimensional shaped object.