Heat Channels in Plastically Deformable 3D Objects
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Solution Overview
Problem
Current additive manufacturing techniques struggle to produce customized, rigid 3D objects that can effectively conform to complex geometries like the human body, particularly for wearable technology and medical applications, as they often rely on expensive and cumbersome 'smart' materials that lack localized deformation control.
Innovation Solution
The integration of heat channels into 3D objects made from thermoplastic materials, such as polyamide and ABS, which allows for localized deformation through controlled heat application, enabling the objects to conform to complex shapes and return to their original form, using conductive agents and electrical stimulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional additive manufacturing techniques are used to produce rigid 3D objects, then structural strength is maintained, but the objects cannot conform to complex geometries like the human body
Solution Approach 1:
The patent applies parameter changes by utilizing the glass transition temperature of thermoplastic materials. By heating the material above its glass transition temperature, the rigid thermoplastic transforms into a plastically deformable state, allowing it to conform to complex geometries. After deformation, cooling below the glass transition temperature restores the material's rigidity and structural strength, thus resolving the contradiction between adaptability and strength.
2Manufacturing precision
If expensive 'smart' materials are used to achieve localized deformation control, then deformation precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies local quality by embedding conductive heat channels selectively within specific regions of the thermoplastic object. These heat channels are positioned precisely where localized deformation is needed, allowing controlled heating and deformation only in those specific areas. This approach achieves deformation precision comparable to smart materials but uses conventional thermoplastics and simple heating elements, significantly reducing manufacturing cost.
3Adaptability or versatility
If thermoplastic materials are used to enable deformation, then adaptability is improved, but the objects lose structural rigidity
Solution Approach 1:
The patent applies periodic action through cyclic heating and cooling of the thermoplastic material. During deformation, the material is heated above its glass transition temperature to enable plastically deformable behavior. After the desired shape change is achieved, cooling below the glass transition temperature restores the material's rigidity. This periodic thermal cycling allows the object to transition between deformable and rigid states as needed, resolving the contradiction between adaptability and structural strength.
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 enables cost-effective, customizable, and flexible production of 3D objects that can adapt to various surface topologies, providing targeted deformation and shape recovery, thus enhancing the usability and effectiveness of wearable devices and medical instruments.
Implementation Method 1
Heat channels formed in the body to deliver an applied stimulus to adjacent regions of the body to soften them
Implementation Method 2
a glass transition temperature and below which the material is rigid and above which the material is plastically deformable
Data Source
AI summary
In one example in accordance with the present disclosure, an additive manufacturing system is described. The additive manufacturing system includes a build material deposition device to form a plastically deformable three-dimensional (3D) object by depositing layers of a thermoplastic build material to form a body of the plastically deformable 3D object. The additive manufacturing system also includes a heat channel forming device to form heat channels within the plastically deformable 3D object which heat channels, responsive to an applied stimulus, are to soften adjacent regions of the body. The additive manufacturing system also includes a fusing system to selectively harden layers of thermoplastic build material to form the plastically deformable 3D object.