Gradual Drying Multi-Material 3D Printing System

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Solution Overview

Problem

Current 3D printing technologies using material jetting face challenges such as slow printing speed, significant shrinkage, and distortion of printed layers due to solvent evaporation and polymerization.

Innovation Solution

A 3D printing system that incorporates a gradual drying process using multiple extraction units and curing stations to rapidly remove the liquid vehicle from printed layers, thereby increasing printing speed, reducing shrinkage, and minimizing distortion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If rapid solvent evaporation is used to increase printing speed, then printing speed is improved, but shrinkage and distortion of printed layers increase

Engineering Contradiction:

Improveprinting speedVSAvoiddimensional accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The drying process is divided into multiple stages using a series of drying stations with progressively increasing extraction capabilities. The printed layer passes through multiple extraction units that gradually remove solvent in controlled amounts, preventing sudden shrinkage while maintaining high throughput. This segmented approach allows speed improvement without sacrificing dimensional accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple intermediate drying stations act as mediators between the printing process and final curing. These stations provide gradual solvent removal with controlled pressure differentials and temperatures, serving as a buffer that prevents direct, rapid evaporation causes shrinkage while still enabling faster processing than traditional single-stage drying.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If traditional single-stage drying is used, then shrinkage is reduced, but printing speed decreases

Engineering Contradiction:

Improvedimensional stabilityVSAvoidprinting speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system maintains continuous operation by implementing a multi-station drying line where printed layers are continuously processed through multiple extraction units. This continuous multi-stage process eliminates idle time between printing and drying while maintaining controlled, gradual solvent removal, thereby achieving both speed and dimensional stability.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system replaces traditional passive air-drying with an active controlled extraction system using pressure differentials and temperature control at multiple stations. This substitution enables much faster solvent removal rates while maintaining dimensional stability through precise control of extraction parameters at each stage.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If multiple extraction units are added to gradually remove liquid vehicle, then shrinkage is reduced, but device complexity increases

Engineering Contradiction:

Improvelayer dimensional accuracyVSAvoidsystem structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Each drying station is designed as a multi-functional unit that combines solvent extraction, temperature control, and layer transport capabilities. This universal design allows the same basic module to be replicated multiple times, reducing overall system complexity through standardization while still providing multi-stage gradual drying functionality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system merges multiple functions into integrated drying stations that combine extraction, heating, and transport operations. By consolidating these functions into unified modules rather than separate components, the system achieves gradual multi-stage drying while minimizing the increase in device complexity through functional integration.

Inventive Principle:

Principle #5Merging (Combining)

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 system achieves faster printing speeds, reduced shrinkage, and minimized distortion of printed layers, while maintaining the fine resolution of inkjet technology.

Implementation Method 1

the time required for solvent evaporation

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

shrinkage because of polymerization

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Data Source

PatentUS12325184B2Method and system of using gradual drying in multi-material 3D printing

Publication Date: 2025.06.10 KERACEL INC

AI summary

A three-dimensional (3D) printer includes a receiver device, a plurality of material deposition units for depositing a material including a particulate material and a liquid vehicle onto the receiver device to form a printed layer on the receiver device, and a material removing system that includes a plurality of extraction units for gradually removing the liquid vehicle from the printed layer. A delivery system of the 3D printer may transport the printed layer from the receiver device to a build platform for stacking a plurality of printed layers and a plurality of post-deposition processing stations may be positioned along the delivery system for performing post-deposition operations on the printed layer.