Inverted Heated Build Chamber for High-Temperature 3D Printing

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Solution Overview

Problem

Current 3D printing technologies are limited in their ability to print high-performance materials at ambient temperatures above 200°C due to temperature constraints imposed by the operating limits of printer components, leading to inadequate layer bonding and mechanical properties in printed parts.

Innovation Solution

A 3D printer design featuring an inverted build chamber with insulated heated side walls and a heated print bed that can maintain temperatures up to 500°C, allowing for the printing of high-performance materials by maintaining a consistent high-temperature environment within the print region.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If traditional 3D printer components are used, then the device complexity is reduced and cost is lowered, but the maximum operating temperature is limited below 200°C

Engineering Contradiction:

Improveprint environment temperatureVSAvoidprinter component specifications

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The build chamber is inverted so that the heated print bed is positioned at the top rather than the bottom. This inversion allows the print head to remain outside the high-temperature zone while still depositing material onto the heated bed, thereby achieving high-temperature printing without requiring all printer components to be high-temperature rated

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The printing system is divided into two distinct thermal zones: a high-temperature zone containing only the print bed and build chamber where material deposition occurs, and a low-temperature zone containing the print head and motion mechanisms. This segmentation allows different components to operate at their optimal temperatures

Inventive Principle:

Principle #1Segmentation

2Temperature

If high-temperature components are used to enable printing above 200°C, then the print environment temperature can be maintained, but the device complexity and cost increase

Engineering Contradiction:

Improvebuild chamber temperatureVSAvoidprinter manufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

High temperature capability is localized only to the print bed and build chamber areas where it is strictly necessary for material deposition and part formation. The rest of the printer mechanism operates at standard temperatures, using conventional, cost-effective components

Inventive Principle:

Principle #3Local quality

3Temperature

If the print head is positioned above the build plate, then the printer structure is simplified, but maintaining high temperature above 200°C becomes difficult

Engineering Contradiction:

Improveprint region temperatureVSAvoidbuild chamber configuration

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #13The other way round (Inversion)

4Strength

If ambient temperature printing is used, then energy consumption is reduced, but layer bonding and mechanical properties deteriorate for high-performance materials

Engineering Contradiction:

Improvelayer bonding qualityVSAvoidheating energy consumption

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The build chamber and print bed are continuously heated and maintained at high temperature throughout the printing process. This continuous thermal environment ensures that each layer is deposited onto a sufficiently hot surface, maintaining consistent layer bonding quality without interruption or temperature fluctuations

Inventive Principle:

Principle #20Continuity of useful action

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

Enables the printing of high-performance materials with improved layer bonding and mechanical properties by maintaining a consistent high-temperature environment, overcoming the temperature limitations of traditional 3D printers and reducing the need for expensive, high-temperature components.

Implementation Method 1

a heater coupled to the inverted build chamber, wherein the heater is configured to heat insulated side walls to 200° C. or greater

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

an insulated heated print bed comprising a print surface

Methodology Applied

Scientific EffectThermal Insulation: Thermal Insulation

Implementation Method 3

an extruder configured to receive, heat, melt, and expel a filament

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS11534970B2High temperature 3D printing via inverted heated build chamber

Publication Date: 2022.12.27 VIRGINIA TECH INTELLECTUAL PROPERTIES INC

AI summary

Described herein are 3D printers capable of printing high-performance materials and uses thereof.