LIFT Slurry Deposition for Faster Deformation-Free 3D Sintering

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Solution Overview

Problem

Existing slurry-based additive manufacturing processes for dental restorations are time-consuming due to lengthy debinding and sintering steps, which can lead to cracking and deformation, and are complicated by the need for separate processing devices and difficulty in changing slurry compositions within a layer.

Innovation Solution

A method utilizing laser-induced forward transfer (LIFT) to deposit slurry layers, which are then processed by electromagnetic radiation for debinding and/or sintering, allowing for integrated, rapid, and controlled layer-wise manufacturing without the need for separate furnaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional slurry-based additive manufacturing processes are used with separate furnaces for debinding and sintering, then the shaped body can be manufactured, but the process is time-consuming and leads to cracking and deformation

Engineering Contradiction:

Improvedeformation-free manufacturingVSAvoidprocess time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent combines multiple processing steps (debinding, sintering, and manufacturing) into a single integrated process using electromagnetic radiation. Instead of using separate furnaces for debinding and sintering, the invention performs all these operations in one device, eliminating the need for multiple separate processing steps and reducing overall process time while maintaining manufacturing precision.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent utilizes parameter changes by varying the electromagnetic radiation characteristics (wavelength, intensity, duration) to achieve different processing effects. By adjusting these parameters, the system can perform debinding at lower temperatures followed by sintering at higher temperatures within the same device, avoiding the time-consuming sequential furnace process and preventing deformation through controlled thermal gradients.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If separate furnaces are used for debinding and sintering, then the processing can be performed, but the device complexity increases and separate processing devices are required

Engineering Contradiction:

Improveintegrated processingVSAvoidnumber of processing devices

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent employs a universal processing device that performs multiple functions: it can manufacture the shaped body additively, perform debinding, and conduct sintering all within a single system. The electromagnetic radiation source and processing chamber serve multiple purposes throughout the manufacturing process, eliminating the need for separate dedicated furnaces for each processing step and simplifying the overall device architecture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If traditional slurry deposition methods are used, then slurry layers can be deposited, but changing slurry compositions within a layer is difficult

Engineering Contradiction:

Improveslurry composition variabilityVSAvoidprocess complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent implements local quality by enabling different slurry compositions to be deposited in different regions or layers of the shaped body. The system can vary slurry properties (such as filler material composition, binder content, or particle size distribution) locally according to the specific requirements of different parts of the restoration, providing compositional versatility while maintaining ease of manufacture through automated control.

Inventive Principle:

Principle #3Local quality

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 high-speed, deformation-free manufacturing of large dental restorations with controlled temperature gradients, eliminating the need for separate processing steps and facilitating varied slurry compositions within a single device.

Implementation Method 1

a laser beam pulses transfer droplets of slurry from a coating on a carrier

Methodology Applied

Scientific EffectLaser induced forward transfer (LIFT): Laser Ablation

Implementation Method 2

directing electromagnetic radiation to the solidified layer for processing it by debinding and/or sintering

Methodology Applied

Scientific EffectElectromagnetic radiation heating: Electromagnetic Induction

Data Source

PatentUS12509400B2Method for layer-wise manufacturing of a shaped body

Publication Date: 2025.12.30 IO TECH GRP LTD

AI summary

A method for layer-wise additive manufacturing of a shaped body made up of slices of processed layers, including the steps:creating a layer of a slurry, the slurry including binder, a dispersing medium and a particulate filler material,solidifying the slurry layer,directing electromagnetic radiation to the solidified layer for processing it by debinding and/or sintering, andrepeating the above-mentioned steps to successively build the shaped body.A laser induced forward transfer (LIFT) process utilizing a laser to direct laser beam pulses acts on a coating of slurry on a carrier to transfer droplets of slurry to a receptor surface to create the slurry layer which is then processed further by above-mentioned steps of solidifying, and debinding and/or sintering.