FDM Outer-Contour Printing With IR-Actuated Gap Filling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional additive manufacturing methods, particularly FDM, suffer from edge gaps and turnaround gaps that lead to weak spots, cracking, and reduced mechanical properties in 3D printed parts.
Innovation Solution
A hybrid printing method combining FDM and IR-actuated material to fill gaps and cracks by using an IR printer to actuate material within the outer contour, eliminating the need for anti-heat agents and enhancing part durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If FDM printing is used to create 3D objects, then material is added layer by layer to form the object, but edge gaps and turnaround gaps are created leading to weak spots and reduced mechanical properties
Solution Approach 1:
The patent combines FDM printing with IR-actuated material deposition to create a hybrid system. The FDM component deposits outer contours and structural elements, while the IR component fills gaps and reinforces weak areas, merging two different manufacturing approaches to eliminate the weaknesses of FDM alone.
Solution Approach 2:
The IR-actuated material is applied specifically at locations where gaps and weak spots occur, such as edge gaps and turnaround gaps. This localized application strengthens only the problematic areas rather than uniformly treating the entire part, optimizing mechanical properties where needed most.
2Device complexity
If conventional FDM printing is used, then the printing process is simple and direct, but anti-heat agents are required to prevent malformation and the process creates weak spots
Solution Approach 1:
The patent converts the harmful effect of heat (which causes malformation) into a beneficial effect by using IR radiation to actuate and deposit additional material precisely where needed. The IR energy that could potentially cause warping is instead used to strengthen the part by filling gaps and reinforcing weak areas.
3Strength
If IR-actuated material is used to fill gaps, then material is deposited to strengthen weak spots, but the process becomes more complex
Solution Approach 1:
The printing system is segmented into distinct functional components: an FDM printing head for depositing outer contours and a separate IR-actuated material deposition system for filling gaps. This segmentation allows each component to perform its specific function optimally while working together in a coordinated manner.
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
The hybrid method strengthens and durably fills gaps, improving mechanical properties and reducing weaknesses in 3D printed parts.
Implementation Method 1
a broadband IR lamp then delivers heat across the entire print bed
Implementation Method 2
This heat is absorbed by the heat absorbing ink, thereby forming a part layer
Implementation Method 3
A hybrid printing method combining FDM and IR-actuated material to fill gaps and cracks by using an IR printer to actuate material within the outer contour
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An apparatus, system and method of additive manufacturing. The apparatus, system and method include at least: a rastering print head suitable to print an outer contour for the additive manufacturing print; a secondary print head suitable to print infrared-actuated print material within the outer counter; and an infrared actuator, suitable to flow the infrared-actuated print material within the outer contour.