Laser Additive Manufacturing of Polymer Strands

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional subtractive manufacturing methods for prototype development and customized manufacturing are time-intensive, labor-intensive, and limit design iteration, hindering collaboration and optimization, while additive manufacturing has not efficiently addressed the production of large objects like tanks and containers from polymer strands.

Innovation Solution

An additive manufacturing system that continuously feeds solid polymer material strands, using laser radiation to liquefy the surface of the strands for bonding, maintaining the central volume in a solid state to ensure strength and flexibility, and re-solidifying for monolithic attachment, enabling the production of large, complex objects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional subtractive manufacturing methods are used for prototype development and customized manufacturing, then design iteration and collaboration are limited, but the time intensity and labor intensity increase significantly

Engineering Contradiction:

Improvedesign iteration speedVSAvoidtime for prototype development

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces traditional mechanical subtractive manufacturing methods with laser-based additive manufacturing. The laser source melts and fuses polymer strands layer by layer to create 3D objects, eliminating the need for mechanical carving or milling. This substitution enables rapid design iteration and significantly reduces prototype development time while maintaining manufacturing precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If additive manufacturing is used to produce large objects like tanks and containers from polymer strands, then manufacturing efficiency improves, but maintaining uniform mechanical properties becomes challenging

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoiduniform mechanical properties

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent employs precise control of laser parameters (power, speed, focal position) and processing parameters (layer thickness, heating temperature, cooling rate) to maintain uniform mechanical properties in large objects. By dynamically adjusting these parameters during the additive manufacturing process, the system ensures consistent material fusion and structural integrity throughout the entire object, regardless of its size or complexity.

Inventive Principle:

Principle #35Parameter changes

3Strength

If the laser heats the surface of polymer strands to liquefy for bonding, then attachment strength improves, but the central volume must remain solid to maintain strength and flexibility

Engineering Contradiction:

Improveattachment strengthVSAvoidsurface temperature control

Core Design Contradiction:

StrengthVSTemperature

Solution Approach 1:

The patent applies localized heating where the laser beam precisely targets only the surface layer of polymer strands at the bonding interface. This creates a molten zone exactly where attachment is needed, while the central volume of the strands remains solid and maintains its structural strength and flexibility. The localized thermal processing ensures optimal attachment strength without compromising the mechanical properties of the bulk material.

Inventive Principle:

Principle #3Local 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 method allows for the efficient and cost-effective production of large, complex objects with uniform mechanical properties, overcoming the limitations of traditional manufacturing by enabling rapid design iteration and collaboration, and producing parts that were previously difficult or expensive to manufacture.

Implementation Method 1

using laser radiation to liquefy the surface of the strands for bonding

Methodology Applied

Scientific EffectLaser radiation heating: Laser

Implementation Method 2

liquefy the surface of the strands

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

re-solidifying for monolithic attachment

Methodology Applied

Scientific EffectRe-solidification: Freezing

Data Source

PatentUS20230256673A1System and method for laser based additive manufacturing

Publication Date: 2023.08.17 LARGIX TECH LTD

AI summary

Systems and methods of laser based additive manufacturing are provided, in which solid polymer material strands are continuously received and have their surfaces melted by laser source(s). Such a system may include a feeder configured to continuously feed, two or more solid polymer material strands, a first guiding unit comprising two or more conduits to continuously receive and guide the two or more solid polymer material strands from the feeder towards a connecting point, a first laser unit, comprising one or more laser sources, each source is directed to deliver a specified laser beam with respect to adjacent surfaces of two adjacent strands towards the connecting point.