FDM Filament with Embedded Conductive Wire for 3D Printed Coils

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Solution Overview

Problem

Conventional 3D printing methods face challenges in integrating electronic components and conductive parts directly into printed objects without separate assembly steps, particularly in achieving reliable electrical connections and embedding complex circuits within the printing process.

Innovation Solution

The method involves using a fused deposition modeling (FDM) 3D printer with filaments containing electrically conductive wires and components, such as LEDs, which are integrated into the printing material, allowing for the direct embedding of electronic circuits and conductive coils within the printed object, enabling inductive communication and power transfer without the need for additional assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional 3D printing methods are used to print objects with electronic components, then the objects can be manufactured with integrated electronics, but the assembly process becomes complex and time-consuming

Engineering Contradiction:

Improveintegration of electronic componentsVSAvoidassembly process

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges electronic components (conductors, LEDs, resistors, capacitors) directly into the 3D printable filament material. This allows all components to be deposited simultaneously in a single printing operation, eliminating complex post-assembly steps while maintaining full integration of electronics within the printed object

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The printable filament is designed to serve multiple functions: it acts as both the structural material and the carrier of electronic components. The filament incorporates conductive wires, electronic components, and insulating materials all in one, allowing a single printing process to create both mechanical structures and functional electronic circuits

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate assembly steps are used to integrate electronic components, then reliable electrical connections can be achieved, but the manufacturing time and productivity decrease

Engineering Contradiction:

Improveelectrical connectionsVSAvoidmanufacturing speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Electronic components and conductive paths are pre-integrated into the filament before printing. This preliminary preparation ensures that when the object is printed, reliable electrical connections are automatically formed as part of the deposition process itself, eliminating the need for separate connection-making steps that would slow production

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If traditional manufacturing methods are used for conductive coils, then precise electrical connections can be made, but the device complexity and assembly steps increase

Engineering Contradiction:

Improveconductive coil placementVSAvoidassembly steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The filament is designed with spatially varying properties: conductive sections for electrical connections, insulating sections for isolation, and component-loaded sections for embedding electronics. This local differentiation allows precise placement of conductive coils and electrical connections to be achieved directly during printing, eliminating complex assembly steps

Inventive Principle:

Principle #3Local quality

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 the creation of 3D printed objects with embedded electronic components and conductive coils, facilitating wireless power transfer and communication, while reducing the complexity of assembly and enhancing the integration of electronic features within the printing process.

Implementation Method 1

FDM works on an 'additive' principle by laying down material in layers; a plastic filament or metal wire is unwound from a coil and supplies material to produce a part. Possibly, (for thermoplastics for example) the filament is melted and extruded before being laid down.

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

enabling inductive communication and power transfer without the need for additional assembly

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS11376785B2Method for manufacturing a 3D item having an electrically conductive coil

Publication Date: 2022.07.05 SIGNIFY HOLDING BV

AI summary

The invention provides a method for manufacturing a 3D item (10) comprising an electrically conductive coil (140) of at least part of an electrically conductive wire (51), wherein the method comprising printing with a fused deposition modeling (FDM) 3D printer (500) 3D printable material (201), wherein the 3D printable material (201) comprises the electrically conductive wire (51), to provide the 3D item (10) comprising the electrically conductive coil (140).