Flexible Sensor for Additive Manufacturing Temperature Monitoring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing bottom-up additive manufacturing devices face challenges in accurately measuring the temperature of the resin at the reaction interface, with non-contact sensors being cumbersome, expensive, and inaccurate, and contact sensors measuring average temperatures rather than specific interface temperatures.
Innovation Solution
An additive manufacturing device with a sensor positioned above the bottom wall in the optical path of the radiation source, constructed to meet transparency and flexibility thresholds, allowing precise temperature sensing of the feedstock material at the reaction interface during polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If non-contact sensors are used to measure temperature at the reaction interface, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent introduces an optically transparent bottom wall as an intermediary medium that allows radiation to pass through while enabling the placement of temperature sensors on the opposite side. This mediator facilitates indirect temperature measurement at the reaction interface without requiring direct contact or complex non-contact sensing arrangements in the resin volume.
Solution Approach 2:
The patent replaces complex non-contact temperature measurement systems with a simpler optical-based approach. By using the optically transparent bottom wall to transmit radiation and enabling sensor placement outside the resin, it substitutes mechanical/optical complexity with a more straightforward transmission-based measurement system.
2Device complexity
If contact temperature sensors are used, then device complexity is reduced, but measurement precision deteriorates as they measure average temperature rather than interface temperature
Solution Approach 1:
The patent applies local quality by positioning the temperature sensor specifically at the bottom wall interface where the reaction occurs. The optically transparent bottom wall enables the sensor to measure temperature at this specific location rather than averaging temperature across the entire resin volume, thus achieving localized temperature measurement with simple contact sensing.
Solution Approach 2:
The optically transparent bottom wall serves as an intermediary that allows the temperature sensor to be positioned at the reaction interface while maintaining optical transmission capability. This enables precise interface temperature measurement without requiring the sensor to be embedded in the resin or use complex non-contact methods.
3Manufacturing precision
If the bottom wall is made optically transparent for radiation transmission, then manufacturing precision is improved, but the sensor's ability to meet both transparency and flexibility thresholds becomes challenging
Solution Approach 1:
The patent addresses the contradiction by changing the material parameters of the bottom wall to achieve both optical transparency and sensor compatibility. The bottom wall is designed with specific optical properties (transparency to radiation wavelengths) while simultaneously being engineered to accommodate temperature sensors, potentially through material selection or structural design that allows sensor integration without compromising optical performance.
Solution Approach 2:
The optically transparent bottom wall is designed to serve multiple functions simultaneously: it transmits radiation for polymerization, provides a mounting surface for temperature sensors, and maintains structural integrity. This multi-functionality reduces the need for separate components and simplifies the overall manufacturing process despite the specialized requirements.
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 accurate and efficient temperature monitoring at the reaction interface, improving the precision and reliability of the additive manufacturing process by ensuring the sensor's transparency and flexibility meet the required thresholds.
Implementation Method 1
a radiation source positioned below the bottom wall which emits radiation in an optical path upward and incident on the bottom wall to polymerize the resin in the container
Data Source
AI summary
An additive manufacturing device includes a container for containing feed stock material and having an optically transparent bottom wall. The additive manufacturing device further includes a radiation source configured to emit radiation in an optical path incident on the bottom wall and a sensor positioned in the optical path of the radiation above the bottom wall. The sensor is configured to sense a temperature of feedstock material at a reaction interface as the radiation polymerizes at least a portion of the feedstock material. The sensor is constructed to meet a transparency threshold and a flexibility threshold.