Heater-Assisted Interlayer Adhesion in FFF 3D Printing
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Solution Overview
Problem
Three-dimensional objects printed using Fused Filament Fabrication (FFF) often exhibit inconsistent material strength along the z-dimension due to weak bonding between layers, resulting in low and inconsistent interlayer strength.
Innovation Solution
A three-dimensional object printing system that includes a platform, a material applicator, and a heater, where the heater is coupled to the material applicator to heat previously deposited layers to a temperature above the transition temperature of the material, weakening intermolecular bonds and improving layer adhesion before subsequent layers are deposited.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If FFF printing deposits successive layers of material on a substrate, then three-dimensional objects can be manufactured additively, but interlayer adhesion is weak and inconsistent
Solution Approach 1:
The system performs preliminary heating of the previously deposited layer before the material applicator deposits the next layer. The heater activates ahead of the material applicator to raise the temperature of the prior layer above the transition temperature of the polymer material, creating a receptive surface that enhances adhesion before the new material is applied.
Solution Approach 2:
The system changes the temperature parameter of the previously deposited layer by heating it above the transition temperature of the polymer material. This temperature change transforms the physical state of the prior layer, making the polymer more pliable and receptive to bonding with the newly deposited material, thereby improving interlayer adhesion.
2Ease of operation
If the material is heated to increase pliability for extrusion, then the material becomes extrudable, but intermolecular bonds weaken reducing material strength
Solution Approach 1:
The heating is applied locally and selectively to the previously deposited layer rather than the entire object or the material in the applicator. The heater targets only the specific region where material adhesion is needed, maintaining localized temperature elevation above the transition temperature without compromising the overall structural integrity of already solidified layers.
Solution Approach 2:
The heating of the previously deposited layer occurs in advance of material deposition. By preparing the surface layer beforehand to be above its transition temperature, the system ensures optimal bonding conditions are established before the new material is extruded and applied, preventing strength degradation in already solidified regions.
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 enhances interlayer strength by allowing polymer strands to intermingle and rearrange, resulting in improved bonding and reduced viscosity, leading to more consistent and stronger three-dimensional objects.
Implementation Method 1
the heater is configured to heat the layer to a temperature greater than a transition temperature of the material forming the object on the platform
Implementation Method 2
When the melter 42 heats the thermoplastic polymer of the filament material 26 above the transition temperature, the intermolecular forces of the material 26 weaken, and the material 26 becomes more pliable and less viscous
Implementation Method 3
the material applicator is configured to expel material to form a layer of an object on the platform
Implementation Method 4
After being deposited by the nozzle 46, the material 26 cools on the member 18 to a temperature below the transition temperature such that the layer 22 becomes less pliable and more viscous and acts as a solid
Data Source
AI summary
A three-dimensional object printing system improves the interlayer adhesion of an object. The printing system includes a platform on which a three-dimensional object is built. A material applicator in the printing system expels material to form layers of the object on the platform. The material applicator also includes a heater configured to heat the layer of the object ahead of the material applicator when the material applicator moves in a first direction and a second direction, both directions being parallel to the platform.