Additive Manufacturing Post-Processing with Fluorescent Binder Agent
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Solution Overview
Problem
In additive manufacturing, distinguishing between the green part and excess build material remnant is challenging due to the transparency of the binder agent, making precise control of the geometry of the final part difficult during the de-caking process.
Innovation Solution
Incorporating an identifiable agent, such as a fluorescent additive, into the binder agent or as a separate component, which becomes distinguishable under specific light sources or heat, allowing for visual differentiation between the green part and excess build material, enabling effective automated cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If binder agent is made transparent to enable curing, then the green part cannot be distinguished from excess build material, but visual differentiation is needed for precise de-caking control
Solution Approach 1:
The patent applies color changes by incorporating pigments or dyes into the binder agent that become visible under specific lighting conditions. The binder agent contains colorants that are invisible or transparent under normal lighting but become highly visible under ultraviolet or infrared illumination, enabling visual differentiation between the green part and excess build material during de-caking without interfering with the curing process
Solution Approach 2:
The patent uses an intermediary substance (fluorescent or phosphorescent material) that is incorporated into the binder agent. This intermediary material absorbs energy from UV or infrared light sources and re-emits it as visible light, creating a visual contrast that allows detection of the green part geometry while maintaining the binder's curing properties
2Productivity
If automated cleaning is implemented to improve productivity, then measurement precision of green part geometry is required, but current transparency prevents accurate detection
Solution Approach 1:
The patent replaces manual visual inspection and mechanical de-caking control with an optical detection system. Sensors equipped with UV or infrared light sources and detectors automatically scan the green part, using the light-responsive binder agent to generate precise geometric data that guides automated de-caking mechanisms, thereby improving both productivity and measurement precision
Solution Approach 2:
The patent implements a feedback system where sensors continuously monitor the green part geometry through the light-responsive binder agent during the de-caking process. The detected geometric information is fed back to control systems that adjust de-caking operations in real-time, ensuring precise removal of excess build material while preserving the green part integrity
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
The use of an identifiable agent facilitates high-contrast imaging and automated removal of excess build material, ensuring precise de-caking and improving the accuracy of the final 3D object geometry before sintering.
Implementation Method 1
an identifiable agent, such as a fluorescent additive, into the binder agent or as a separate component, which becomes distinguishable under specific light sources or heat
Data Source
AI summary
In one example a system is for post-processing a three-dimensional (3D) object generated in an additive manufacturing process in which an identifiable agent is applied to a portion of a build material to form a portion of the 3D object. The system comprises an identification unit and a sensor. The identification unit is to cause the identifiable agent to become distinguishable to thereby cause the portion of the 3D object, corresponding to the portion of build material to which the identifiable agent was applied, to be distinguishable from any build material remnant disposed on the 3D object and to which no identifiable agent was applied. The sensor is to distinguish the build material remnant from the portion of the 3D object.