Insulating Element with Functional Openings for 3D Printing Heat Control
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Solution Overview
Problem
Existing layer construction methods for producing three-dimensional objects face challenges in achieving uniform temperature distribution and efficient heat input, particularly as the component height increases, leading to decreased heat flow and irregular temperature distributions due to preheating methods from below or above.
Innovation Solution
A continuous production process where the application of construction material, preheating, and selective solidification occur simultaneously through a device with a construction platform, preheating and solidification radiation sources, and an insulating element with functional openings for material and radiation passage, allowing for independent movement of components to optimize heat input and temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If preheating is carried out by heating the assembly platform from below, then the construction material can be preheated before selective solidification, but with increasing component height the heat flow decreases due to losses and increasing volume of bulk powder
Solution Approach 1:
The patent inverts the conventional preheating approach by heating the construction material from above rather than from below. This is achieved by providing a radiating member that emits radiation onto the construction material, allowing heat to be applied directly to the material surface without having to conduct heat through the entire powder bed volume, thereby reducing heat loss and maintaining effective heat flow regardless of component height
Solution Approach 2:
The patent introduces a radiating member as an intermediary between the heat source and the construction material. This radiating member efficiently transfers thermal energy to the construction material through radiation, enabling effective preheating without direct contact and minimizing heat loss to the surrounding environment and assembly platform
2Temperature
If preheating is carried out by supplying heat from above using temporarily heatable devices, then heat can be applied to the construction material, but irregular temperature distribution occurs requiring complicated controls and expensive measures
Solution Approach 1:
The patent changes the fundamental parameter of heat transfer mode from conductive heating through temporarily heatable devices to radiative heating. The radiating member emits thermal radiation that penetrates and heats the construction material more uniformly, eliminating the need for complex control systems and expensive measures to achieve uniform temperature distribution
3Manufacturing precision
If cycled production with sequential preheating and selective hardening is used, then each layer can be properly prepared and solidified, but manufacturing speed decreases due to the cyclic nature of the process
Solution Approach 1:
The patent implements continuous production by simultaneously performing material application, preheating, and selective solidification in an unbroken sequence. The radiating member continuously preheats the construction material while the solidification source simultaneously solidifies the required areas, eliminating idle time between cycles and significantly increasing manufacturing speed while maintaining layer quality
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 efficient and optimized heat input, eliminating the need for uniform temperature distribution, allowing for non-uniform temperatures at different points, and improving manufacturing speed and efficiency by decoupling radiation and solidification source movements.
Implementation Method 1
at least one preheating radiation source for introducing thermal energy into the construction material
Implementation Method 2
at least one solidification radiation source for selective solidification of construction material by local heating
Implementation Method 3
In a laser sintering process, a plastic material is preheated to a temperature below the sintering temperature. The energy introduced by the laser then only contributes to the differential heat quantity for melting the powder particles
Implementation Method 4
the insulating element has at least two functional openings that can be used simultaneously, one of the at least two functional openings being designed as a material passage and another of the at least two functional openings being designed as a radiation passage
Data Source
Figure 1
Figure 2
Figure 3a~3e
AI summary
The invention relates to a device (1) and a method for producing three-dimensional objects (3) by selectively solidifying a layered build-up material (4). To improve the manufacturing process, in particular to optimize the heat input, the use of an insulating element (6) with at least two functional openings (18, 19) is proposed, wherein one of the at least two functional openings serves as a material passage (18) and another of the at least two functional openings simultaneously serves as a radiation passage (19, 20).