Fluid-Fluid Interface for Oxygen Removal in Vat Polymerization
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Solution Overview
Problem
Conventional additive manufacturing processes face inefficiencies due to adhesion between printed objects and vat surfaces, leading to increased costs and compromised structural integrity caused by elevated levels of undesirable gases like oxygen, which affect polymerization consistency and resolution.
Innovation Solution
A system and method utilizing a fluid-fluid interface and gas transport system, where a first fluid treated with an inert gas is circulated to modify the gas content within a second fluid, preventing adhesion and reducing oxygen levels, thereby enhancing print resolution and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive manufacturing processes are used with inverted layer-by-layer printing in a vat of photopolymer resin, then higher resolution and reduced resin volume are achieved, but the printed object adheres to the bottom surface of the vat requiring slow and time-consuming detachment processes
Solution Approach 1:
The patent introduces a fluid processing surface that acts as an intermediary between the printed object and the vat bottom. This fluid layer prevents direct adhesion between the printed object and the solid vat surface, allowing for rapid object release without compromising print resolution. The fluid medium enables both high-resolution printing and efficient object detachment.
2Ease of operation
If processes are used to alter composition of liquid or vat surfaces to remedy surface adhesion, then adhesion issues are addressed, but preexisting problems are magnified and negative effects increase
Solution Approach 1:
The patent employs an inert gas atmosphere (such as nitrogen or argon) in the processing environment to prevent unwanted chemical reactions and maintain processing consistency. This inert environment addresses adhesion control while preventing the magnification of negative effects that occurs with compositional alterations, as the inert atmosphere does not interfere with the photopolymerization process or material properties.
3Adaptability or versatility
If elevated levels of undesirable gases such as oxygen are present in the vat and at the processing surface, then gas transport occurs, but polymerization across individual layers becomes inconsistent resulting in compromised mechanical and structural integrity
Solution Approach 1:
The patent extracts or removes undesirable gases (particularly oxygen) from the processing environment through the fluid processing surface system. By taking out these harmful gases from the vat atmosphere and replacing them with inert gases, the system prevents oxygen interference with polymerization, ensuring consistent polymerization across layers and maintaining structural integrity of printed objects.
4Manufacturing precision
If the presence of oxygen and other gases affects polymerization consistency, then resolution is compromised, but processing time increases to maintain quality
Solution Approach 1:
The patent establishes continuous circulation of the fluid processing surface and maintains a continuous inert gas atmosphere throughout the printing process. This continuous approach prevents oxygen recontamination and maintains consistent polymerization conditions without requiring intermittent processing interruptions or extended curing times, thereby achieving high resolution without significant time loss.
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
This approach eliminates adhesion issues, expands the range of printable materials, improves print times and resolution, especially at smaller scales, and ensures continuous printing without layer delamination, resulting in higher-quality, structurally sound objects.
Implementation Method 1
gases diffuse at the liquid-liquid interface between the liquid and the photopolymer resin to remove oxygen from the photopolymer resin and into the liquid
Implementation Method 2
The light source projects light incident on the outer surface of the transparent portion of the vat such that the light is incident on the liquid-liquid interface
Data Source
AI summary
Disclosed herein are embodiments of a system for use in additive manufacturing methods. The system can comprise a first container, and a first fluid and a second fluid forming a fluid-fluid interface within the first container. The first fluid is between the fluid-fluid interface and the transparent portion of the first container and configured to remove oxygen from the second fluid at the fluid-fluid interface to facilitate polymerization of a monomeric component in the second fluid. The system can also comprise a circulation system configured to circulate the first fluid through the first container such that the first fluid flows between the fluid-fluid interface and the inner surface of the transparent portion of the first container.