FDM 3D Printing With Light-Transmissive Particles for Sparkling Effects
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Solution Overview
Problem
Existing 3D printing methods for manufacturing luminaire or lighting device components lack the ability to create an aesthetic or decorative optical effect by interacting with light emitted by the device.
Innovation Solution
A method of fused deposition modeling that incorporates light transmissive particles into a thermoplastic polymer, where the ratio of particle width to layer width is at least 0.6, forming pinholes that create a sparkling light effect when illuminated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If light transmissive particles are embedded in a planar optical element with particle diameter equal to element thickness, then refraction of light provides crystal or glitter effect, but the optical element remains planar and limited in decorative versatility
Solution Approach 1:
The patent transitions from planar 2D optical elements to three-dimensional printed objects with varying thicknesses and complex geometries. The FDM process enables particles to be embedded within volumetric structures rather than flat surfaces, allowing light to interact with the object from multiple angles and creating dynamic optical effects that change with viewing perspective.
Solution Approach 2:
The invention varies the thickness parameter of the optical element at different locations to optimize light interaction. By controlling the distance between the light source and the particle embedding locations through 3D printing, the patent achieves enhanced refraction and reflection effects that create sparkling appearances, unlike uniform planar elements.
2Ease of manufacture
If FDM printing is used to manufacture luminaire components, then manufacturing complexity is reduced and production is simplified, but the ability to create aesthetic optical effects by interacting with light is lacking
Solution Approach 1:
The patent combines thermoplastic polymer material with light-transmissive particles to create a composite printable material. This composite enables the FDM printing process to directly produce components with embedded optical effects, merging the manufacturing simplicity of FDM with the aesthetic qualities of particle-based light interaction.
Solution Approach 2:
The invention places light-transmissive particles at specific locations within the 3D printed structure where they will optimally interact with light. The particle distribution and positioning are controlled during printing to create localized sparkling effects in areas that will be illuminated, while other areas maintain structural functionality.
3Illumination intensity
If particles are embedded in 3D printed material with particle width to layer width ratio of at least 0.6, then pinholes are formed that create sparkling light effect, but manufacturing precision requirements increase
Solution Approach 1:
The patent establishes a specific parameter range for particle width to layer width ratio (at least 0.6) to ensure optimal pinhole formation. This parameter control creates the right balance where particles are large enough to form effective pinholes for light transmission while maintaining compatibility with standard FDM printing capabilities.
Solution Approach 2:
The light-transmissive particles serve a dual function: they act as fillers in the composite material and simultaneously create the pinhole structures necessary for optical effects. The particles self-organize during printing to form the light-transmissive pathways, eliminating the need for separate pinhole creation steps.
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 method produces a 3D item with a sparkling light effect, enhancing the aesthetic appearance of luminaire or lighting devices by interacting with light emitted by the light source.
Implementation Method 1
The particles, and the material they are embedded in, are light transmissive, so that refraction of light by the particles can provide a crystal or glitter effect.
Data Source
AI summary
The invention relates to a method of manufacturing a 3D item by means of fused deposition modeling. The method comprises the step of depositing a 3D printable material to form a layer stack of 3D printed material, wherein each layer of the layer stack has a layer height and a layer width. The 3D printable material comprises a thermoplastic polymer and light transmissive particles. The layer stack comprises a plurality of the light transmissive particles, each light transmissive particle having a particle width, being the dimension of the light transmissive particle in a direction parallel to the layer width. For the plurality of light transmissive particles, each ratio of the particle width and the layer width is at least 0.6 so that, in the layer stack, the plurality of light transmissive particles forms a plurality of pinholes delimited by a wall part. When the 3D item is illuminated by a light source, the pinholes create relatively small virtual light sources on the surface of the 3D item, opposite to the surface that is illuminated by the light source, thereby providing a sparkling light effect for an observer looking at the 3D item.