In-Bath Additive Manufacturing of Silicone Elastomers
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Solution Overview
Problem
Current additive manufacturing methods lack the ability to vary material characteristics within a component during production and are unable to efficiently produce strong, resilient, and dimensionally stable silicone elastomer components, particularly at room temperature.
Innovation Solution
The method involves using a bath of silicone gel with a dispenser of a liquid catalyst to actively cross-link and accelerate the hardening of the material, allowing for variation of characteristics such as hardness, flexibility, and color by changing the curing agent, enabling the production of components with multiple properties and geometries without the need for molding or casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a bath of liquid base material is used with successive layer solidification, then uniform material characteristics are achieved, but the ability to vary material characteristics within the component is lost
Solution Approach 1:
The patent applies local quality by enabling different material characteristics at different locations within the component. The digital model allows specification of varying material properties (such as density, strength, or composition) for different regions of the component, and the additive manufacturing process deposits material accordingly, achieving spatially varying material characteristics while maintaining overall composition stability through controlled layer-by-layer construction.
2Ease of manufacture
If conventional additive manufacturing methods are used, then simple geometries can be produced, but complex geometries and multi-grade components cannot be achieved
Solution Approach 1:
The patent applies dynamics by implementing a dynamic and flexible manufacturing process that can adapt to complex geometries. The digital model serves as a dynamic blueprint that can be modified to specify varying material characteristics and complex shapes, and the additive manufacturing process dynamically adjusts material deposition patterns, layer thicknesses, and construction sequences to achieve the desired complex geometries and multi-grade components.
3Manufacturing precision
If material is removed by conventional machining techniques, then precise shapes can be achieved, but material waste and process complexity increase
Solution Approach 1:
The patent applies preliminary action by using additive manufacturing to build components directly from digital models, constructing the final shape by adding material layer-by-layer according to precise digital specifications. This eliminates the need for preliminary roughing operations and subsequent precision machining, achieving manufacturing precision through the digital design and controlled material deposition process itself, while minimizing material waste since only the necessary material is deposited.
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 allows for the rapid production of three-dimensional components with varied properties, including strength, resilience, and visual characteristics, enabling the creation of complex geometries and multi-grade silicone components, enhancing the versatility and efficiency of additive manufacturing.
Implementation Method 1
dispensing a fluid curing agent in said bath in a pattern defined by a digital record, said curing agent converting said base material to a solid in the vicinity thereof
Implementation Method 2
The catalyst may cause a controlled vulcanisation of the silicone gel, which accelerates a hardening of the fluid base material in the vicinity of the catalyst
Data Source
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AI summary
A method and device for producing a three-dimensional component byin-bath additive manufacturing comprising a bath (12) of a first fluid component and a nozzle (15) for dispensing a second fluid component. In use the nozzle is moved in the bath, and the fluid components react to produce said component. The second fluid component may be varied to change the visual and/or physical properties of the component. A computer (24) contains a digital record to control respective position of the nozzle and the bath.