Hybrid 3D Printing Process for High-Strength Multi-Material Objects
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Solution Overview
Problem
Current 3D printing technologies face limitations in producing mechanically stable and resilient objects with high resolution, as they often require low viscosity materials, are multi-material limited, and result in objects with short lifespan due to high temperature sensitivity and high material consumption.
Innovation Solution
A hybrid 3D printing process using a low viscosity first material for shaping and a higher viscosity second material for building, where the first material is dissolved after solidification, allowing for multi-material objects with enhanced mechanical strength and surface quality, and enabling continuous printing without additional manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If low viscosity materials are used for inkjet printing, then printing resolution and surface quality are improved, but mechanical stability and durability of the printed object deteriorate
Solution Approach 1:
The patent divides the printed object into two distinct materials: a first material (resin) applied in fine droplets for high-resolution shaping, and a second material (polymer) applied in larger portions for structural strength. The first material provides manufacturing precision through its low viscosity enabling fine droplet deposition, while the second material provides mechanical stability through its higher viscosity and structural integrity.
Solution Approach 2:
The patent creates a composite structure by combining two different materials with complementary properties. The first material (low viscosity resin) is used for precise geometric formation, while the second material (higher viscosity polymer) is used for providing mechanical strength. This composite approach allows the object to simultaneously achieve high printing resolution and mechanical stability.
2Device complexity
If single material is used for 3D printing, then process simplicity is maintained, but adaptability and versatility are limited
Solution Approach 1:
The patent segments the material application process into two distinct steps: first applying the low viscosity resin material for shaping, then applying the higher viscosity polymer material for structuring. This segmentation enables multi-material printing while maintaining relative process simplicity through a systematic two-stage approach.
Solution Approach 2:
The patent implements multi-functionality by using the same printing system to deposit two different materials with different properties. The first material serves the function of geometric definition and support, while the second material serves the function of providing mechanical strength. This universal approach allows a single printing system to create objects with diverse material properties.
3Productivity
If high temperature filling material is used in injection molding, then productivity is improved, but object lifespan and durability deteriorate due to heat sensitivity
Solution Approach 1:
The patent replaces the thermal injection molding process with a UV-curing process. Instead of using high temperature to solidify the material, the patent uses UV radiation to cure the polymer layers. This substitution eliminates the heat sensitivity issue that limits object lifespan, while maintaining productivity through rapid UV curing of each layer.
Solution Approach 2:
The patent utilizes UV-induced phase transition (liquid polymer to solid through crosslinking) instead of thermal phase transition (melting and solidifying). The UV radiation triggers polymer crosslinking, transforming the material from liquid to solid state without requiring high temperatures, thus preserving object durability while maintaining manufacturing efficiency.
4Manufacturing precision
If layer-by-layer material application is used, then manufacturing precision is improved, but productivity and printing time worsen
Solution Approach 1:
The patent implements continuous material application by applying the first material layer, immediately applying the second material layer on top, and then UV curing both layers together. This continuous process eliminates idle time between material applications and maintains precise layer thickness control while improving overall printing speed through uninterrupted material deposition and simultaneous curing.
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 the production of objects with high mechanical stability and surface quality, allowing for complex geometries and multi-material properties, while reducing material waste and extending object lifespan.
Implementation Method 1
liquid polymers which can be solidified by exposure to ultraviolet radiation are used as the first and second materials
Implementation Method 2
The resulting bottom layer of material is irradiated with ultraviolet radiation in a further step to solidify the polymers contained in the first and second materials by crosslinking. After the bottom layer of material has been completed, further layers of material are applied and solidified in a similar manner until all layers of the molded article have been produced and solidified. The resulting stack of layers is then brought into contact with the solvent until the first material dissolves.
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
In a method of producing a three-dimensional mould and a three-dimensional moulded article (1) by means of layer-by-layer material application, geometric data for the moulded article (1), a carrier part (2) having a base area (3) for accommodating the three-dimensional moulded article (1), a consolidatable first and second material (4, 5) are provided. The second material (5) has a higher strength in the consolidated state than the solidified first material (4). The consolidated first material (4) is dissolvable in the solvent. For formation of a negative mould layer (12), material portions of the free-flowing first material (4) are applied in accordance with the geometric data to the base area (3) and/or a material layer of the three-dimensional moulded article (1) present thereon in such a way that the negative mould layer (12) has at least one cavity (13) that has a negative mould of a material layer of the moulded article (1) to be produced. The negative mould layer (12) is consolidated. For formation of a moulded article layer (16), the cavity (13) is filled with a second material (5) and then the second material (5) is consolidated. By means of a plane disposed at a predetermined distance from the base area (3), protruding regions of the consolidated negative mould layer (12) and/or moulded article layer (16) are removed by material removal. The aforementioned steps are repeated at least once. The negative mould layers (12) are contacted with the solvent in such a way that the consolidated first material (4) dissolves in a solvent.