Jetted Material Printer Vacuum Solvent Extraction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing material jetting technologies face challenges in efficiently removing solvents from printed material layers without adversely affecting the quality of the printed material, as solvent removal often results in the loss of binders and other components, leading to deteriorated material properties.
Innovation Solution
A jetted material printing system that includes a carrier substrate, printheads for depositing material, a liquid removal device for solvent extraction using a pressure differential or vacuum, and a binder conditioning device for replenishing binders lost during solvent removal, ensuring the quality and integrity of the printed layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If vacuum removal is used to remove solvent from jetted material, then removal speed is improved, but binder loss and material quality deterioration occur
Solution Approach 1:
A receiver substrate acts as an intermediary component between the jetted material and the vacuum source. The receiver substrate is positioned to receive the jetted material at an angle, allowing solvent removal while preventing direct contact between the vacuum source and the jetted material, thereby preventing binder loss.
Solution Approach 2:
The system segments the solvent removal process into distinct functional components: the jetted material deposition zone, the receiver substrate reception zone, and the vacuum source zone. This segmentation allows each component to perform its specific function without interfering with others, enabling efficient solvent removal while preserving binder integrity.
2Reliability
If thermal removal is used to remove solvent, then binder preservation is improved, but processing time increases
Solution Approach 1:
The patent replaces thermal removal (heat-based mechanism) with vacuum-based mechanical removal. The vacuum source creates a pressure differential that mechanically extracts solvent from the jetted material without requiring thermal energy, thereby reducing processing time while maintaining binder preservation through the intermediary receiver substrate.
3Productivity
If continuous material jetting is used for high-speed printing, then productivity is improved, but solvent dilution and packing density reduction occur
Solution Approach 1:
The system performs preliminary solvent removal action immediately after material jetting, before the solvent can cause significant dilution. The receiver substrate is positioned to receive and facilitate solvent removal from freshly jetted material, preventing solvent-related packing density reduction while maintaining continuous high-speed printing operations.
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
The system effectively removes solvents from printed material layers while maintaining the desired binder levels, thereby preserving the quality and integrity of the printed material, enabling efficient and high-quality 3D printing processes.
Implementation Method 1
the solvent is removed after the material jetting to reduce dilution of the powder and increase the packing density of the jetted material. Removal of the solvent is typically performed in one of two (2) ways: thermal removal or vacuum removal
Implementation Method 2
Vacuum removal is typically faster than thermal removal. However, during vacuum removal, in addition to the solvent, the powder, the binder and any additives that may be present in the jetted material may also be removed
Data Source
AI summary
A jetted material printing system includes a carrier substrate configured to travel along a longitudinal direction thereof, one or more printheads, each of the one or more printheads being configured to deposit an amount of material onto the carrier substrate to form a printed layer, a liquid removal device located at a first position from the one or more printheads in the longitudinal direction, and a binder conditioning device located downstream from the liquid removal device in the longitudinal direction and over the carrier substrate. A method of jetted material printing includes depositing material from one or more printheads onto a carrier substrate, the material including at least a powder, a binder and a solvent, removing the solvent from the jetted material, and conditioning the jetted material.