Layered 3D Printing with Low Viscosity Fluid Fill
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Solution Overview
Problem
Additive manufacturing (3D printing) processes are slow in producing large or detailed parts, and existing methods fail to effectively increase the strength and structural integrity of the produced products.
Innovation Solution
The method involves dispensing a solidifiable fluid into the pores or cavities of the additive manufactured object using a 3D printer with multiple applicators to create a multilayer structure, where a second fluid is injected to fill cavities, solidify, and bond with the multilayer wall, generating residual compressive stress and mechanical interlocking for enhanced strength and faster cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional additive manufacturing is used to produce large or detailed parts, then manufacturing precision is maintained, but productivity is low
Solution Approach 1:
The manufacturing process is divided into two distinct phases: a first additive manufacturing pass that creates the basic multilayer wall structure with controlled porosity, and a second filling pass that injects fluid through the porous structure to complete the parts. This segmentation allows each phase to be optimized independently, with the first pass focusing on structural accuracy and the second pass focusing on rapid filling to reduce overall cycle time.
Solution Approach 2:
The first fluid is deposited to create a porous multilayer wall structure with controlled porosity and interconnected pores. This porous structure serves as a scaffold that enables rapid injection and filling by the second fluid, dramatically reducing the time required to fill cavities compared to traditional solid-layer-by-layer methods, while maintaining manufacturing precision through the controlled porosity design.
2Strength
If traditional additive manufacturing is used, then structural integrity is achieved, but the strength of produced products is insufficient
Solution Approach 1:
The final product is created as a composite structure combining the porous multilayer wall (first fluid) with the filling material (second fluid). The first fluid forms a skeletal framework that provides structural shape and initial strength, while the second fluid fills the pores and cavities to create a dense, strong composite material. This composite approach achieves superior load-carrying capacity compared to traditional single-material additive manufacturing, while the rapid filling process maintains high productivity.
Solution Approach 2:
The porous multilayer wall structure is created first as a preliminary framework before the second fluid is injected. This preliminary structure provides the necessary form and initial structural integrity, and its controlled porosity is specifically designed to facilitate rapid filling by the second fluid. The preliminary action of creating the porous scaffold enables the subsequent rapid filling, achieving both high strength and short cycle time.
3Device complexity
If a single fluid is used for both layer deposition and cavity filling, then device complexity is reduced, but manufacturing precision and productivity are compromised
Solution Approach 1:
The manufacturing process is segmented into two distinct phases with different material requirements: first fluid for layer deposition and second fluid for cavity filling. This segmentation allows each fluid to be optimized for its specific function, with the first fluid formulated for controlled layer deposition and the second fluid formulated for rapid injection and filling, thereby improving productivity without excessive device complexity.
Solution Approach 2:
The invention utilizes parameter changes in fluid viscosity and composition between the first and second fluids. The first fluid has properties optimized for layer-by-layer deposition, while the second fluid has lower viscosity and different composition optimized for rapid injection through porous structures. These parameter changes enable each fluid to perform its specific function optimally, improving overall manufacturing efficiency.
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 significantly reduces manufacturing cycle time and increases the strength and load-carrying capacity of the 3D printed products by filling cavities with a second fluid that solidifies within the object, creating a stronger and more structurally sound final product.
Implementation Method 1
bonding to the multilayer wall through mechanical interlocking and/or residual compressive stress generation
Implementation Method 2
bonding to the multilayer wall through mechanical interlocking and/or residual compressive stress generation
Data Source
AI summary
Example 3D printing methods involve rapid liquid filling of one or more cavities within a hollow and/or porous 3D printed object. In some examples, a conventional applicator computer-controllably dispenses significantly viscous solidifiable fluid in layers to build up a side wall of the object, and that same applicator or another applicator discharges a second solidifiable fluid at relatively low viscosity to rapidly fill the cavity(s), voids and/or porosity defined by the accurately printed side wall. In some examples, the liquid fill solidifies to permanently embed an internal object (e.g., wire or fiberglass mesh, Kevlar fabric, acrylic, bullet resistant armor, structural reinforcing material, etc.). In some examples, the liquid fill material permanently bonds to the accurately printed side wall. In some examples, the liquid fill material shrinks upon solidifying to create beneficial residual compressive stress within the 3D printed side wall and/or within the solidified material itself. In some examples, the liquid fill material does not solidify and is non-Newtonian to improve impact resistance.