Liquid Metal Jetting Perimeter and Infill Solidification Control
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Solution Overview
Problem
Conventional 3D printing technologies face challenges in optimizing the printing of perimeters and infills with 3D liquid metal jet printers, as they struggle to balance drop spreading and solidification to achieve precise geometrical accuracy and mechanical properties simultaneously.
Innovation Solution
A method and system where a 3D printer controls different parameters for ejecting drops to form perimeters and infills, such as varying drop size, speed, temperature, and frequency, to ensure perimeters solidify quickly with minimal spreading and infills solidify more slowly with greater spreading, thereby optimizing spot size and layer height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the same printing parameters are used for both perimeter and infill, then the printing process is simple, but the geometrical accuracy and mechanical properties cannot be optimized simultaneously
Solution Approach 1:
The printing process is segmented into two distinct modes: perimeter printing and infill printing. Each mode uses independently optimized parameters, allowing the system to achieve high geometrical accuracy for perimeters while maintaining productivity for infills, without requiring a single complex parameter set
Solution Approach 2:
Different printing parameters are applied to different regions of the part. Perimeter regions receive parameters optimized for precision and minimal spreading, while infill regions receive parameters optimized for productivity and bonding, achieving local optimization without compromising the other
2Productivity
If drops are ejected with high frequency to improve productivity, then printing speed increases, but drop spreading increases and geometrical accuracy decreases
Solution Approach 1:
The ejector frequency is made dynamic rather than fixed. The system automatically adjusts frequency based on the current printing mode (perimeter or infill), enabling high frequency during infill printing for productivity while maintaining lower frequency during perimeter printing for geometrical accuracy
Solution Approach 2:
The printing process alternates between different frequency regimes periodically. High-frequency ejection is applied during infill deposition to maximize productivity, while low-frequency ejection is applied during perimeter deposition to ensure precision, creating a periodic pattern of parameter variation
3Manufacturing precision
If drops are cooled quickly to solidify perimeters for precision, then geometrical accuracy improves, but the drops spread less and bonding may be compromised
Solution Approach 1:
The solidification process is segmented into two phases: perimeter solidification and infill solidification. Perimeter drops are rapidly cooled to achieve minimal spreading and high geometrical accuracy, while infill drops are allowed to cool more slowly to ensure adequate spreading and bonding
4Strength
If drops are allowed to spread more for better infill bonding, then mechanical properties improve, but spot size increases and geometrical accuracy decreases
Solution Approach 1:
Different spot size characteristics are applied to different regions. Perimeter drops maintain small spot sizes for geometrical accuracy, while infill drops are allowed to develop larger spot sizes for improved bonding, with each region's quality characteristics optimized independently
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 enhances the geometrical quality and mechanical properties of 3D parts by allowing precise drop placement and improved bonding, while maintaining productivity, by achieving distinct solidification phases for perimeters and infills.
Implementation Method 1
The drops fall onto a build plate where they cool and solidify to form a 3D part
Data Source
AI summary
A method for printing a 3D part with a 3D printer includes ejecting drops of a build material from a nozzle of the 3D printer. A first plurality of the drops forms a perimeter of the 3D part, and a second plurality of the drops forms an infill of the 3D part. The method also includes controlling a parameter such that the parameter has a first value while the first plurality of the drops is ejected. The method also includes controlling the parameter such that the parameter has a second value while the second plurality of the drops is ejected, wherein the first and second values are different.