3D Printed Latticed Conductive Elements With Lower Metal Bleeding
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Solution Overview
Problem
Existing additive manufacturing processes face challenges in efficiently incorporating conductive elements into 3D printed objects, leading to increased material costs, asymmetrical conductivity, and reduced dimensional accuracy due to excess metal usage and bleeding of conductive agents.
Innovation Solution
The system generates latticed conductive elements using a model generator and controller to selectively deposit conductive agents in a lattice pattern, reducing overall metal usage while maintaining desired conductivity and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive agents are deposited in traditional additive manufacturing processes, then conductive elements are incorporated into 3D printed objects, but material costs increase and dimensional accuracy decreases due to excess metal usage and bleeding
Solution Approach 1:
The conductive element is divided into a lattice structure consisting of multiple discrete struts arranged in a geometric pattern. This segmentation allows conductive material to be placed only where electrically necessary, rather than filling the entire volume, thereby reducing material usage and preventing bleeding while maintaining conductivity pathways.
Solution Approach 2:
The lattice structure provides different material densities and conductive properties at different locations within the conductive element. By concentrating conductive material along the strut members and leaving voids between them, the structure achieves optimal conductivity along current pathways while reducing overall material content and preventing excess metal bleeding into surrounding areas.
2Reliability
If traditional additive manufacturing processes are used to incorporate conductive elements, then conductive pathways are created, but material costs increase due to excessive metal usage
Solution Approach 1:
The conductive element is divided into a lattice structure consisting of multiple discrete struts arranged in a geometric pattern. This segmentation allows conductive material to be placed only where electrically necessary, rather than filling the entire volume, thereby reducing material usage and preventing bleeding while maintaining conductivity pathways.
Solution Approach 2:
The lattice structure creates a porous or hollow internal geometry with voids between the strut members. This porous configuration maintains electrical conductivity through the connected struts while significantly reducing the quantity of conductive material required compared to solid structures, thereby lowering material costs.
3Reliability
If conductive agents are deposited in traditional additive manufacturing processes, then conductive elements are formed, but thermal effects increase due to excess metal content
Solution Approach 1:
The conductive element is divided into a lattice structure consisting of multiple discrete struts arranged in a geometric pattern. This segmentation allows conductive material to be placed only where electrically necessary, rather than filling the entire volume, thereby reducing material usage and preventing bleeding while maintaining conductivity pathways.
Solution Approach 2:
The lattice structure creates a porous or hollow internal geometry with voids between the strut members. This porous configuration maintains electrical conductivity through the connected struts while significantly reducing the quantity of conductive material required compared to solid structures, thereby lowering material costs.
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 conserves valuable metal, enhances conductivity, ensures dimensional accuracy, and reduces thermal effects, making it suitable for integrating conductive elements into 3D printed objects with improved mechanical properties.
Implementation Method 1
Additive manufacturing systems form a three-dimensional (3D) object through the solidification of layers of build material
Implementation Method 2
The build material is then exposed to energy such as electromagnetic radiation... Due to the increased heat absorption properties imparted by the fusing agent, those portions of the build material that have the fusing agent disposed thereon heat to a temperature greater than the fusing temperature
Implementation Method 3
The fusing agent disposed in the desired pattern increases the energy absorption of the layer of build material on which the agent is disposed
Implementation Method 4
those portions of the build material that have the fusing agent disposed thereon heat to a temperature greater than the fusing temperature for the build material
Implementation Method 5
as energy is applied to a surface of the build material, the build material that has received the fusing agent, and therefore has increased energy absorption characteristics, fuses
Implementation Method 6
the build material that has received the fusing agent, and therefore has increased energy absorption characteristics, fuses while that portion of the build material that has not received the agent remains in powder form
Data Source
AI summary
In one example in accordance with the present disclosure, a system is described. The system includes a model generator that includes a processor and memory. The model generator obtains an input that indicates a property of a conductive element to be printed and obtains a template which defines a lattice structure for the conductive element. The model generator also generates a latticed conductive element model based on the template and the input. The system also includes a three-dimensional printing controller to trigger selective hardening of build material to form the latticed conductive element.