Laser Transfer 3D Printing for High Throughput
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Solution Overview
Problem
Existing 3D printing methods are not suitable for producing precision objects with high throughput, as they have low throughputs (well below 1 kg/h) and are restricted by the chemical and physical properties of the print materials.
Innovation Solution
A novel 3D printing method using laser transfer printing, which involves irradiating a print material on a transparent carrier cylinder with a laser to detach and transfer it to a base plate, allowing for high-throughput production of objects without impairing print quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional 3D printing methods are used, then print quality can be maintained, but throughput is limited to well below 1 kg/h
Solution Approach 1:
The patent replaces conventional mechanical deposition methods with laser-induced forward transfer (LIFT). A laser beam irradiates the print material on the carrier cylinder, causing localized heating and detachment of material that transfers to the base plate. This optical/thermal mechanism enables higher throughput while maintaining precision, as the laser can be rapidly scanned and controlled with high accuracy.
Solution Approach 2:
The patent changes the physical state and parameters of the print material through laser irradiation. The laser energy causes localized heating, phase changes, and material ejection dynamics that enable rapid transfer. By controlling laser parameters (power, pulse duration, scanning speed), the system achieves both high throughput and precise material placement.
2Adaptability or versatility
If conventional 3D printing methods are used, then process simplicity is maintained, but material selection is restricted by chemical and physical properties
Solution Approach 1:
The LIFT system serves multiple functions: it can process diverse materials (polymers, metals, ceramics, composites) using the same basic mechanism. The laser parameters can be adjusted to accommodate different material properties, making the system universally applicable to various print materials without requiring fundamentally different processing approaches.
Solution Approach 2:
By dynamically adjusting laser parameters (wavelength, power, pulse duration, scanning speed) and carrier cylinder rotation speed, the system adapts to different material properties. This parameter control enables processing of materials with varying chemical and physical characteristics while maintaining a relatively simple overall process structure.
3Productivity
If laser transfer printing is implemented, then throughput increases to above 1 kg/h, but process complexity increases
Solution Approach 1:
The print material is pre-applied to the carrier cylinder surface before the printing process begins. This preliminary coating step allows the laser to simply detach and transfer material during printing, rather than depositing material layer by layer. The carrier cylinder rotation is also pre-synchronized with laser scanning, enabling continuous high-speed processing.
Solution Approach 2:
The carrier cylinder acts as an intermediary between the print material source and the base plate. Material is deposited on the rotating carrier, then transferred to the base plate via laser irradiation. This intermediary approach enables continuous material supply and rapid transfer, increasing throughput while keeping the printing station relatively simple.
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 method enables the printing of objects with a high throughput of greater than 1 kg/h while maintaining high print quality, and is suitable for a multitude of different print materials.
Implementation Method 1
irradiating the carrier cylinder (51) with laser beams (50a) from the laser source (50), such that at least a portion of the applied print material (54) is detached from the carrier cylinder (51) and transferred to the plate (28)
Implementation Method 2
irradiation is effected in such a way that the laser beams (50a) (i) hit the print material (54) directly through the carrier cylinder (51) from outside the carrier cylinder (51)
Data Source
AI summary
The invention relates to a 3D printing method for the layer-by-layer fabrication of objects using laser transfer printing, and to a 3D printing device for carrying out the method. According to the method, a printing compound (54) applied to a carrier cylinder (51) is irradiated with a laser (50), detached, and transferred to a base plate (27). The resulting printing compound layers are subsequently cured and the process repeated until the object is completely built up. Using said claimed method, objects can be printed from a variety of possible printing materials with high throughput (over 1 kg/h) without affecting the print quality.