Humidity-Compensating Activator Control for Binder Jetting

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Solution Overview

Problem

Humidity affects the properties of build materials in additive manufacturing, causing them to clump and stick together, which impacts the consistency and excavability of objects created, particularly in binder jetting processes.

Innovation Solution

A system and method for controlling the amount of activator used based on ambient humidity levels, utilizing a controller that takes humidity readings and adjusts the activator deposition accordingly, ensuring consistent results and easy drainage of excess build material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a fixed amount of activator is deposited regardless of humidity, then the process is simple to operate, but the manufacturing precision and consistency of the object deteriorate due to humidity-induced clumping

Engineering Contradiction:

Improveconsistency of object formationVSAvoidcomplexity of activator control system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system employs a humidity sensor to continuously monitor ambient humidity levels and feeds this information back to the controller, which then adjusts the activator deposition amount dynamically. This closed-loop feedback mechanism ensures consistent object formation by compensating for humidity variations without requiring complex manual intervention.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system uses ambient humidity information naturally present in the environment to self-adjust the activator deposition process. The humidity sensor and controller work together to automatically compensate for environmental conditions, making the system self-regulating and improving consistency without adding significant operational complexity.

Inventive Principle:

Principle #25Self-service

2Manufacturing precision

If more activator is deposited to compensate for high humidity, then object formation consistency improves, but activator consumption increases

Engineering Contradiction:

Improveconsistency of object formationVSAvoidactivator consumption

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The system dynamically changes the activator deposition parameter (amount) based on measured humidity levels. During high humidity conditions, the system increases activator deposition to maintain consistency, while during low humidity conditions, it reduces deposition to conserve activator. This parameter adjustment is calculated to optimize both consistency and resource efficiency.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system applies partial activator deposition during low humidity conditions and excessive (increased) deposition during high humidity conditions, adjusting the amount precisely to what is needed for consistent object formation. This prevents both waste during dry conditions and insufficient activation during humid conditions.

Inventive Principle:

Principle #16Partial or excessive action

3Strength

If activator amount is increased to ensure proper bonding, then object strength improves, but drainage of excess build material becomes difficult

Engineering Contradiction:

Improvebond strength of objectVSAvoidexcavability of remaining material

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The system adjusts the activator deposition parameter based on humidity levels to achieve optimal bonding strength without excessive activator accumulation. By precisely controlling the amount deposited, the system ensures sufficient activation for strong bonding while maintaining proper drainage characteristics of excess build material, avoiding the need for excavation difficulties.

Inventive Principle:

Principle #35Parameter changes

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 ensures consistent object formation and easy excavation by compensating for moisture in the air, conserving activator and facilitating proper drainage of remaining build material, thereby improving the precision and efficiency of additive manufacturing processes.

Implementation Method 1

A controller may be configured to take humidity readings from one or more humidity sensors

Methodology Applied

Scientific EffectHumidity sensing: Hygrometer

Implementation Method 2

The activator may be allowed to soak through the deposited build material

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentUS11584067B2Humidity compensating activator control for additive manufacturing

Publication Date: 2023.02.21 LAMONCHA MARK

AI summary

Systems and method for additive manufacturing with humidity compensation are provided. A first reservoir for activator, a second reservoir for binder, and a third reservoir for build material to be deposited within a build box by way of one or more deposit devices are provided. A controller receives data indicating ambient humidity level from a humidity sensor and commands a control device associated with the first reservoir to adjust an amount of activator removed from the first reservoir based on the ambient humidity level.