3D Printer Laser Surface Treatment Module
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Solution Overview
Problem
Existing surface treatment systems for 3D objects require multi-step processes or chemical modifications to alter physical properties, and existing 3D printers lack simplicity and precision in selectively treating surfaces for specific purposes.
Innovation Solution
A 3D printing system equipped with a surface treatment module that uses a pulsed, focused laser beam to alter physical properties of individual layers and selective areas within layers during the additive manufacturing process, allowing for precise control over the formation of micro and nano-structures to repel or attract water.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-step processes or chemical surface modifications are used to alter physical properties, then the physical properties (water repellency/attractivity) can be enhanced, but the process complexity increases
Solution Approach 1:
The patent extracts the surface treatment function from separate multi-step chemical processes and integrates it directly into the 3D printing system through a laser module. The laser module is positioned to treat the build material immediately after ejection onto the build plate, eliminating the need for post-processing chemical modifications and reducing overall process complexity
Solution Approach 2:
The patent combines the 3D printing process with surface treatment into a single integrated system. The laser module is incorporated into the printer to treat surfaces during the manufacturing process itself, merging two previously separate operations (printing and surface treatment) into one unified process that reduces complexity
2Adaptability or versatility
If selective surface treatment is implemented to pattern specific properties on object surfaces, then the functionality for specific purposes is improved, but the system complexity increases
Solution Approach 1:
The patent applies local quality by enabling the laser module to treat only specific regions of the build material surface. The controller receives instructions to direct the laser beam to predetermined locations on each layer, creating spatially varying surface properties (hydrophobic/hydrophilic patterns) only where needed, rather than treating the entire surface uniformly
Solution Approach 2:
The laser module serves multiple functions: it cures the build material (as in traditional SLA printing) and simultaneously performs selective surface treatment to create patterned surface properties. This multi-functionality is achieved through a single integrated module controlled by software, avoiding the need for separate treatment systems
3Manufacturing precision
If precise control of build material ejection is used to form micro and macro features, then the surface structure precision is improved, but the system complexity and number of ejectors required increases
Solution Approach 1:
The patent replaces complex mechanical ejector systems with a laser-based approach. Instead of using multiple specialized ejectors of different sizes to create micro and macro features, the system uses a single laser module that can selectively treat the surface of ejected material to create the desired micro-features, simplifying the mechanical complexity
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 creation of complex surface features with enhanced water-repellent or water-attracting properties without additional coatings, simplifying the treatment process and improving the precision of surface modifications in 3D printing.
Implementation Method 1
moving a focused, pulsed UV laser beam to predetermined locations on a layer of the object being formed by the 3D object printer to cure the build material at the predetermined locations and alter a physical property of the layer at the predetermined locations
Data Source
AI summary
A three-dimensional (3D) object printer includes a surface treatment system configured to treat layers of an object being formed by the printer with a moving ultraviolet (UV) laser. The movement of the laser is controlled with a scanning mirror system and the spot size of the laser is reduced with a focus lens having a numerical aperture in a range of about 0.5 to about 1.0.