Flexible 3D Printing Module for Defect Correction

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Solution Overview

Problem

Current 3D printing technologies face difficulties in accurately correcting complex cracks and anomalies in objects due to the challenge of applying material in intricate shapes and dimensions, often resulting in incomplete or improper repair.

Innovation Solution

A flexible wrapper-shaped printing module with an array of dynamically interchangeable port openings that can function as injection nozzles or suction ports, allowing for precise deposition and filling of 3D printable material into defects while creating backpressure to prevent air passage, using a combination of injection and suction pressures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional 3D printing methods are used to correct defects, then the printing process is simple, but the ability to accurately fill complex cracks and anomalies is insufficient

Engineering Contradiction:

Improvedefect filling accuracyVSAvoidprinting module structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The printing module is segmented into multiple independent port openings distributed across the flexible wrapper surface. Each port can be independently controlled to inject or suction material, allowing precise targeting of complex defect geometries without requiring a single complex nozzle structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The port openings serve multiple functions: they can act as injection nozzles for material deposition, suction ports for removing air or excess material, or remain closed depending on the operational requirements. This multi-functionality reduces the need for separate specialized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If material is injected into defects without backpressure, then the injection process is simple, but air passages remain and filling is incomplete

Engineering Contradiction:

Improvedefect filling completenessVSAvoidpressure control system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The injection and suction functions are merged into a single integrated printing module. The flexible wrapper with multiple ports allows simultaneous or sequential injection and suction operations at different locations, creating backpressure to prevent air passages while filling defects completely.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system uses pneumatic control through the flexible wrapper ports to manage material flow. By coordinating injection pressure from selected ports with suction pressure from other ports, the system creates the necessary backpressure to ensure complete defect filling without air pockets.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Adaptability or versatility

If a rigid printing module is used, then the structure is stable, but the module cannot adapt to various defect shapes and locations

Engineering Contradiction:

Improvedefect shape accommodationVSAvoidmodule structural stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The printing module uses a flexible wrapper made of compliant material that can conform to the surface geometry of the object and adapt to various defect shapes and locations. The flexible membrane maintains structural integrity while allowing the port array to conform to curved or irregular surfaces.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible wrapper allows the printing module to dynamically adapt its shape and port orientation to match the defect geometry. The module transitions from a fixed configuration to a conformal configuration that matches the underlying surface, enabling versatile defect correction while maintaining structural stability through the flexible material properties.

Inventive Principle:

Principle #15Dynamics

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 effective correction of complex cracks and anomalies by ensuring proper filling and solidification of materials, addressing the limitations of existing 3D printing technologies in handling intricate defect shapes and dimensions.

Implementation Method 1

allow the 3D printable material to move through a first set of selected port openings of the array of port openings and be injected into the defect

Methodology Applied

Scientific EffectInjection pressure: Pressure Increase

Implementation Method 2

a source of suction that is adapted to introduce a backpressure to a second set of selected port openings of the array of port openings

Methodology Applied

Scientific EffectSuction: Suction

Implementation Method 3

The layers can each be cured, for example, via exposure to UV light, solidifying them into solid material matching the CAD model

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Data Source

PatentUS12097670B2Method and system for three-dimensional printing-based correction of defects in objects

Publication Date: 2024.09.24 INTERNATIONAL BUSINESS MACHINE CORPORATION

AI summary

An apparatus for correcting a defect in an object using three-dimensional (3D) printing. The apparatus includes a flexible wrapper-shaped printing module including an array of port openings adapted to allow a 3D printable material to move therethrough. The flexible wrapper-shaped printing module is configured to wrap around an object to allow the 3D printable material to move through a first set of selected port openings of the array of port openings and be injected into the defect in order to correct the defect.