Heat Energy Filter for Selective Infrared Wavelengths in Additive Manufacturing
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Solution Overview
Problem
High-speed sintering (HSS) in additive manufacturing is limited to polyamides due to the use of broadband IR lamps, which fail to deliver targeted heat to other materials, leading to malformation and reduced recyclability of powder materials.
Innovation Solution
A heat energy filtering system is introduced between the broadband IR energy source and the print bed, allowing for selective filtering of infrared wavelengths to match the specific requirements of various polymer types, enabling targeted heating and preventing undesired activation of materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If broadband IR lamps are used for high-speed sintering, then heating coverage is improved, but manufacturing precision deteriorates due to inability to deliver targeted heat
Solution Approach 1:
The broadband IR spectrum is segmented into multiple wavelength bands using filter wheels with different bandpass filters. Each filter isolates specific wavelength ranges that correspond to absorption peaks of different polymer materials, allowing selective heating of targeted areas while preventing overheating of surrounding regions.
Solution Approach 2:
The system applies different wavelength filters to different spatial locations and time periods based on the specific polymer material being processed. This local quality adjustment ensures that each area receives the precise wavelength spectrum required by the local material properties, achieving both broad coverage and targeted precision.
2Productivity
If broadband IR lamps are used for high-speed sintering, then productivity is improved, but manufacturing precision deteriorates leading to part malformation
Solution Approach 1:
The filter wheel system dynamically switches between different wavelength filters during the sintering process based on real-time detection of polymer material types and their specific absorption characteristics. This dynamic adaptation maintains high processing speeds while ensuring geometric accuracy by matching the IR wavelength to the material's absorption peak.
Solution Approach 2:
The system changes the spectral parameters of the IR radiation by selecting different bandpass filters that correspond to different wavelength ranges. This parameter change allows the same broadband IR source to be optimized for different polymer materials, maintaining both productivity and manufacturing precision across diverse materials.
3Device complexity
If broadband IR lamps are used without wavelength filtering, then device complexity is reduced, but adaptability deteriorates limiting material selection to polyamides only
Solution Approach 1:
The filter wheel assembly enables a single broadband IR lamp to serve multiple functions by sequentially applying different wavelength filters that match the absorption characteristics of various polymer materials. This multi-functionality extends material compatibility beyond polyamides to include other polymers without requiring separate IR sources for each material type.
Solution Approach 2:
The bandpass filters act as intermediaries between the broadband IR source and the diverse polymer materials. These filters translate the broad spectrum into material-specific wavelength ranges, enabling the simple broadband source to effectively process multiple material types while maintaining controlled device complexity.
4Use of energy by moving object
If broadband IR heat is applied without filtering, then energy efficiency is improved through full spectrum utilization, but manufacturing precision deteriorates causing undesired material activation
Solution Approach 1:
The system uses partial action by applying only the specific wavelength portion of the IR spectrum that is needed for each material, rather than the full broadband spectrum. This selective wavelength application prevents energy waste on non-absorbed wavelengths while avoiding undesired activation of materials, achieving both energy efficiency and manufacturing precision.
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 solution allows for the use of a broader range of materials in HSS, preventing malformation and enabling more efficient recycling of powder materials by ensuring precise heat application, thereby enhancing the versatility and accuracy of the printing process.
Implementation Method 1
broadband IR energy source...heat energy filter...allowing for selective filtering of infrared wavelengths...match the specific requirements of various polymer types
Implementation Method 2
broadband IR energy source suitable to pass over the print bed...deliver targeted heat...heating and preventing undesired activation of materials
Implementation Method 3
heat energy filter...filtering of infrared wavelengths to match the specific requirements of various polymer types...ensuring precise heat application
Data Source
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AI summary
An apparatus, system and method for additive manufacturing. The apparatus, system and method include at least a print bed having thereon powdered print material; a dispersing head suitable to disperse one or more heat-actuated agents onto the powdered print material as indicated by a print plan; a broadband infrared energy source suitable to pass over the print bed so as to actuate the dispersed agent; and a heat energy filter interfaced to the broadband energy source so as to filter the actuating energy to one or a range of wavelengths of the infrared energy source that is less than the available broadband.