Heat Shrink Coating for 3D Printed Optical Lighting
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Solution Overview
Problem
Objects manufactured by fused deposition modeling (FDM) often exhibit a characteristic ribbed surface structure, which is not desirable for applications requiring a smooth surface, such as lighting devices where optical functions like reflection are needed.
Innovation Solution
A method involving 3D printing a light transmissive layer stack and applying a heat shrink that conforms to the printed material, providing optical effects like refraction, diffraction, reflection, diffusion, or conversion, to achieve a smooth surface and enhance optical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If FDM 3D printing is used to manufacture objects, then productivity and manufacturing capability are improved, but the surface structure becomes ribbed and rough instead of smooth
Solution Approach 1:
The heat shrink is applied to the 3D printed object before final use, preliminarily smoothing the ribbed surface structure. This preliminary action removes the surface defect without requiring post-processing steps like polishing or solvent treatment, thus maintaining high productivity while achieving smooth surface quality.
Solution Approach 2:
The heat shrink process changes the temperature parameter of the 3D printed object, causing the ribbed surface structure to shrink and smooth out. By controlling the temperature parameter during the heat shrink application, the surface morphology is transformed from rough to smooth while preserving the underlying geometry.
2Manufacturing precision
If post-processing steps like polishing or solvent treatment are applied to smooth the surface, then surface smoothness is improved, but manufacturing time and process complexity increase
Solution Approach 1:
The invention extracts the surface smoothing function from the 3D printed object itself by applying a separate heat shrink layer. Instead of modifying the printed object directly through time-consuming polishing or solvent treatment, the smoothing action is transferred to an applied heat shrink layer that conforms to the object's surface, dramatically reducing post-processing time.
Solution Approach 2:
The heat shrink acts as an intermediary between the ribbed 3D printed surface and the desired smooth finish. Rather than directly polishing or chemically treating the printed surface, the heat shrink mediates the smoothing process by conforming to the underlying geometry and providing a smooth outer surface, thereby eliminating time-consuming direct post-processing steps.
3Manufacturing precision
If a heat shrink is applied to smooth the surface, then surface smoothness and optical performance are improved, but an additional material layer and process step are added
Solution Approach 1:
The heat shrink serves multiple functions simultaneously: it smooths the ribbed surface structure, provides the desired optical properties (transparency, reflectivity, diffusion), and protects the 3D printed object. By combining multiple functions into a single component, the invention adds minimal process complexity while achieving comprehensive surface improvement and optical performance.
Solution Approach 2:
The final object becomes a composite structure combining the 3D printed base material with the heat shrink overlay. This composite material approach allows the heat shrink to provide surface smoothing and optical properties that the printed material alone cannot achieve, while the two materials work together to create the final functional object with enhanced properties.
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 method results in a smooth surface for FDM objects, improving their aesthetic and technical performance, particularly in lighting applications by enhancing optical effects such as reflection, diffraction, and light transmission.
Implementation Method 1
applying heat to shrink the heat shrink so that the inner heat shrink surface is in physical contact with the outer stack surface
Implementation Method 2
the heat shrink is arranged to provide an optical effect chosen from the group consisting of refraction, diffraction, reflection, diffusion and conversion
Implementation Method 3
the heat shrink is arranged to provide an optical effect chosen from the group consisting of refraction, diffraction, reflection, diffusion and conversion
Implementation Method 4
the heat shrink is arranged to provide an optical effect chosen from the group consisting of refraction, diffraction, reflection, diffusion and conversion
Data Source
Figure 1
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
The invention provides a 3D printed object (210) and a method of manufacturing such an object (210) by means of fused deposition modelling. The method successively comprises the steps of (i) 3D printing a printable material (120) to create a layer stack (230) of printed material (210), wherein the layer stack (210) bounds a space (240), wherein the layer stack (210) has an inner stack surface (231) and an outer stack surface (232), the inner stack surface (231) facing towards the space (240) and the outer stack surface (232) facing away from the space (240), (ii) providing a heat shrink (250) onto the layer stack (230), wherein the heat shrink (250) has an inner heat shrink surface (251) and an outer heat shrink surface (252), the inner heat shrink surface (251) facing towards the outer stack surface (232) and the outer heat shrink surface (252) facing away from the outer stack surface (232), and (iii) applying heat to shrink (250) the heat shrink so that the inner heat shrink surface (251) is in physical contact with the outer stack surface (232) and the heat shrink (250) is conformal to the layer stack (230). The layer stack (230) is light transmissive, and the heat shrink (250) is arranged to provide an optical effect chosen from the group consisting of refraction, diffraction, reflection, diffusion and conversion. The 3D printed object (210) may be used as a component of a lighting device (600), such as a lampshade.