Laser Preheating for FDM Layer Adhesion
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Solution Overview
Problem
Fused deposition modeling 3D printing systems face challenges in creating strong bonds between adjacent layers, especially when using high-temperature thermoplastics in ambient temperature environments, as existing methods often require ovenized environments and can lead to energy wastage and material degradation.
Innovation Solution
A method involving a laser preheater that selectively irradiates the tool path with a laser image, heating the thermoplastic material to a material-specific bonding temperature without exceeding the degradation temperature, allowing for localized energy input to facilitate adhesion between layers, reducing the need for a high-heat build environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a high-heat build environment (ovenized environment) is used to ensure strong layer bonds, then layer adhesion is improved, but energy consumption increases and material degradation risk increases
Solution Approach 1:
The laser preheater performs preliminary heating of the tool path and previously deposited material before the extrusion head deposits new material. This preliminary action ensures the substrate is at the optimal bonding temperature when new material arrives, eliminating the need for sustained high-heat environment and reducing overall energy consumption
Solution Approach 2:
Instead of heating the entire build environment uniformly, the laser preheater applies heat locally only to the specific tool path area where material will be deposited. This localized heating achieves the necessary bonding temperature at the interface without requiring the entire build chamber to be heated, significantly reducing energy consumption
2Strength
If a high-heat build environment is used to ensure strong layer bonds, then layer adhesion is improved, but material degradation risk increases
Solution Approach 1:
The laser preheater heats the tool path and previously deposited material just before material deposition occurs. This timing ensures material is heated to bonding temperature only when needed, avoiding prolonged exposure to high temperatures that would cause degradation while still achieving strong adhesion
Solution Approach 2:
The laser preheater confines high temperature to only the immediate tool path area where bonding occurs, rather than heating the entire build environment. This localized approach prevents material in other areas from being exposed to degrading high temperatures while still achieving adequate bonding temperature at the deposition interface
3Use of energy by moving object
If selective laser preheating is used to reduce energy consumption, then energy efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The laser preheater acts as an intermediary device between the extrusion head and the previously deposited material. It mediates the thermal state of the substrate to ensure optimal bonding conditions without requiring complex modifications to the extrusion head or build environment, adding a dedicated function that simplifies the overall control architecture
Solution Approach 2:
The patent replaces the mechanical/thermal approach of heating the entire build environment with an optical approach using a laser preheater. This substitution allows for precise, localized energy delivery through light-matter interaction, achieving better energy efficiency with a relatively simple optical system rather than a complex thermal management system
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 enhances layer adhesion, reduces energy wastage, and prevents material degradation by targeting only the necessary areas for preheating, enabling strong bonds between layers without the need for an ovenized environment, thus improving part quality and efficiency.
Implementation Method 1
selectively irradiate the thermoplastic material of the partially printed part with a field of light energy having a power intensity sufficient to heat the thermoplastic material irradiated by the laser image to a temperature at or above a material-specific bonding temperature
Implementation Method 2
The bead of thermoplastic material is deposited from the extrusion head along the tool path while the thermoplastic material irradiated by the laser image remains at or above the material-specific bonding temperature, so that diffusion occurs between part layers
Data Source
AI summary
A method for additive manufacturing a part using fused deposition modeling 3D printing technology includes projecting a laser image from one or more laser emitters onto a previously printed bead or beads of thermoplastic material forming a portion of the part, along a tool path for a next bead in a subsequent part layer. The laser image has a width of between about 50% to 75% of a commanded beadwidth of the next bead, and is moved along a tool path that is generally transverse to the width thereof, to thereby selectively irradiate and heat the previously printed thermoplastic material to at least a bonding temperature thereof but below a degradation temperature. A bead of thermoplastic material is extruded from an extrusion head and deposited along the tool path while at least a top surface portion of the irradiated material remains at or above its bonding temperature, so that strong adhesion occurs between part layers.