FDM Fluidic Device Sealing via Overlapping Bead Deposition
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Solution Overview
Problem
Fused Deposition Modeling (FDM) technologies face limitations in creating sealed fluidic devices due to gaps between neighboring bead deposits, leading to leakage issues when fabricating fluidic devices with unsupported features and restricted material choices, particularly in diagnostic and biological applications where material interactions with fluids are critical.
Innovation Solution
The use of predetermined commands to control the dispensing of material in FDM, allowing for closed loops and lateral overlaps in layer deposition, along with arcuate paths for abrupt direction changes, minimizes leakage by ensuring material overlap and optimal layer formation, enabling the creation of sealed fluidic devices with complex geometries and varied materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If material is deposited in circular bead patterns using conventional FDM, then the manufacturing process is simple and fast, but gaps form between neighboring beads creating leak paths
Solution Approach 1:
The patent applies preliminary action by planning and executing material overlap in advance during the deposition process. The controller is programmed to deposit subsequent beads with intentional overlap onto previous beads, proactively preventing gap formation before leak paths can develop. This predetermined overlap strategy ensures sealing quality without requiring complex post-processing.
Solution Approach 2:
The patent implements local quality by varying the deposition pattern in different regions of the fluidic device. In areas requiring sealing (channel walls and interfaces), overlapping bead patterns are used to eliminate gaps. In non-critical areas, conventional non-overlapping patterns may be used to maintain manufacturing simplicity. This localized approach optimizes sealing quality where needed while preserving overall process efficiency.
2Adaptability or versatility
If FDM is used to fabricate fluidic devices, then a wide range of polymer materials can be used, but gaps between beads cause fluid leakage
Solution Approach 1:
The controller is pre-programmed with deposition paths that incorporate overlapping patterns for all fluid-containing structures. This preliminary planning ensures that regardless of which polymer material is selected (ABS, polypropylene, COC, polycarbonate, polystyrene, or other biocompatible materials), the sealing geometry is consistently achieved through predetermined material overlap, maintaining fluid sealing reliability across all material choices.
3Reliability
If material overlap is implemented to seal gaps, then leakage is reduced, but material deposition control becomes more complex
Solution Approach 1:
The system employs feedback mechanisms where the controller monitors deposition progress and automatically adjusts subsequent bead placement to achieve the desired overlap. The controller receives position feedback from the deposition system and uses this information to calculate and execute the precise overlap required for sealing, transforming a potentially complex manual process into an automated feedback-controlled operation that reduces leakage while managing complexity through intelligent control.
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 reduces leakage and enhances the manufacturing of fluidic devices with precise control over material deposition, allowing for the production of sealed devices with complex features and varied materials, suitable for diagnostic and biological applications, while optimizing material properties for specific uses.
Implementation Method 1
The material is heated inside the nozzle to a semiliquid state and is then extruded through the exit of the nozzle and deposited onto the part
Implementation Method 2
The material is heated inside the nozzle to a semiliquid state
Implementation Method 3
The nozzle can be moved in both horizontal and vertical directions by a numerically controlled mechanism
Data Source
Figure 1
Figure 2A~2C
Figure 3
AI summary
An apparatus (10) for creating a three dimensional device (100). The apparatus comprises a dispensing head (14) for dispensing material, and a base member (16) for receiving the material dispensed from the dispensing head (14). A controller (20) is provided for controlling the operation of the apparatus (10). The apparatus is operable to create the three dimensional device (100) by depositing a series of line deposits of material from the dispensing head (14) based on predetermined commands sent by the controller (20). The controller (20) is operable to control how the line deposits are dispensed to improve the sealing properties of the device (100).