Flow Infill 3D Printing with Covalent Layer Bonding
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Solution Overview
Problem
Conventional 3D printing methods using thermoplastic materials face limitations in creating strong, structurally integrated objects due to reliance on adhesion bonds between layers, which can be compromised by solvent resistance and thermal resistance.
Innovation Solution
Utilizing coreactive materials with covalent bonding capabilities, controlled by a computer system to generate tool paths and dispense boundary and infill materials, enabling covalent bonding between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoplastic material is used with adhesion bonds between layers, then the manufacturing process is simple and layers can be easily deposited, but the structural integrity and mechanical properties are compromised due to weak bonding
Solution Approach 1:
The patent changes the chemical bonding parameter from physical adhesion (thermoplastic) to covalent bonding (coreactive materials). The coreactive materials undergo a chemical reaction to form covalent bonds between layers, fundamentally changing the bonding mechanism from weak physical adhesion to strong chemical bonding, thereby resolving the contradiction between ease of manufacture and structural integrity
Solution Approach 2:
The patent uses composite materials consisting of coreactive materials that combine reactive functional groups with structural components. These composite materials enable covalent bonding between layers while maintaining processability, resolving the contradiction by integrating both ease of deposition and strong bonding capabilities into a single material system
2Ease of operation
If conventional thermoplastic materials are used, then the printing process is straightforward with sequential layer deposition, but solvent resistance and thermal resistance are compromised
Solution Approach 1:
The patent changes the material parameter from thermoplastic to coreactive material, which undergoes chemical crosslinking to form a network structure. This parameter change provides excellent solvent and thermal resistance while maintaining relatively simple printing operation through controlled material dispensing and in-situ curing
Solution Approach 2:
The patent replaces the mechanical cooling and solidification process of thermoplastics with a chemical curing process. The coreactive materials are deposited and then cured through chemical reaction (photo-curing, thermal curing, or moisture curing), substituting the mechanical phase change with a chemical transformation that provides superior solvent and thermal resistance
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
Enhances structural integrity and mechanical properties of 3D printed objects by forming covalent bonds within layers, improving solvent and thermal resistance.
Implementation Method 1
coreactive materials with covalent bonding capabilities, controlled by a computer system to generate tool paths and dispense boundary and infill materials, enabling covalent bonding between layers
Data Source
Figure 1
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Figure 3A~3B
AI summary
A computer system for part production using flow infill design receives a computer-aided design (CAD) file that describes physical dimensions of a target object. The computer system identifies a physical boundary portion of the target object within the CAD file. The computer system generates a first tool path to additively manufacture the physical boundary portion. Additionally, the computer system sends instructions to a computer system in communication with a dispenser that cause the dispenser to implement the first tool path while dispensing a boundary material. Further, the computer system generates a command to dispense the coreactive infill material within the physical boundary portion.