FDM Thread Formation for Optical Textures
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Solution Overview
Problem
Current additive manufacturing technologies, such as FDM, face limitations in producing 3D printed items with specific structures and optical properties, particularly for creating textures like spider webs or optical elements with tailored effects, often requiring complex solutions or non-3D printed components.
Innovation Solution
A method using FDM with a printer nozzle that alternates between depositing and interrupting the flow of material to create threads with specific thickness and length, allowing for the formation of structures where layers are connected vertically and suspended in air, enabling the production of items with unique optical properties and textures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional FDM continuous deposition is used, then manufacturing speed is maintained, but complex structures with suspended threads and specific optical textures cannot be produced
Solution Approach 1:
The patent applies periodic action by alternating between material deposition phases and material interruption phases. During deposition phases, material is extruded to form connected layers; during interruption phases, material flow is stopped to allow thread formation by pulling. This periodic switching enables the creation of suspended thread structures with spider web textures that cannot be achieved with continuous deposition, while maintaining manufacturing simplicity through automated control of the extrusion process.
2Shape
If photo-polymerisable materials are used for smooth surfaces, then surface quality is improved, but thermal conductivity and material stability deteriorate
Solution Approach 1:
The patent applies parameter changes by modifying the material state during the printing process. The thermoplastic material is heated to a molten state for extrusion, then allowed to cool and solidify, forming suspended threads. This phase change approach enables the creation of smooth surfaces and complex geometries using thermoplastic materials that offer superior thermal conductivity and stability compared to photo-polymerisable materials, eliminating the need for post-printing smoothing operations.
3Illumination intensity
If conventional layer deposition is used, then manufacturing speed is maintained, but optical properties and light transmissive control are limited
Solution Approach 1:
The patent applies periodic action by implementing alternating deposition and interruption cycles. During deposition phases, material is extruded to create connected layers with good structural integrity; during interruption phases, material flow is stopped to allow threads to form and suspend in air, creating regions with different optical densities. This enables precise control over light transmissive properties and optical effects while maintaining overall printing efficiency through automated process 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
Enables the creation of 3D printed items with specific structures and optical properties, such as threads that can be used to form letters or signs, and control light transmissive properties, offering an alternative to traditional methods by producing complex geometries and optical effects.
Implementation Method 1
pulling with the printer nozzle first 3D printable material away from the start support element... a thread of first 3D printed material is formed
Data Source
Figure 1A~1B
Figure 1C~2B
Figure 3A~3B
AI summary
The invention provides a method for producing a 3D item (1) by means of fused deposition modelling using a fused deposition modeling 3D printer (500) comprising a printer nozzle (502), the method comprising a 3D printing stage comprising depositing an extrudate (321) comprising 3D printable material (201), to provide the 3D item (1) comprising 3D printed material (202), wherein the 3D printing stage comprises a thread formation stage comprising: (i) depositing at a substrate (1550) at a first position (1551) first 3D printable material (1201) to provide a start support element (1561) of first 3D printed material (1202), wherein the substrate (1550) is selected from a receiver item (550) and already 3D printed material (202) on the receiver item (550); (ii) changing during a transport stage the horizontal position of the nozzle (502) relative to the first position (1551) to a second position (1552), while during the transport stage pulling with the printer nozzle (502) first 3D printable material (1201) away from the start support element (1561) while controlling a flow of first 3D printable material (201) from the nozzle (502) such that a thread (323) of first 3D printed material (1202) is formed; and (iii) depositing at the substrate (1550) at the second position (1552) first 3D printable material (1201) to provide an end support element (1562) of first 3D printed material (1202) for the thread (323).