Localized Layer Heating for Stronger 3D Print Interlayer Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current additive manufacturing methods face challenges in achieving strong adhesion and reduced porosity between layers, leading to suboptimal mechanical, thermal, and electrical properties of 3D printed objects due to the deposition of layers below their melting temperature.
Innovation Solution
The method involves creating a 'melt pool' in the current layer using an energy source like a laser or hot fluid before depositing the next layer, enhancing diffusion and mixing between layers, and using composite filament materials with specific cross-sectional shapes and modifiers to improve bonding and properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If layers are deposited in conventional additive manufacturing, then the 3D object is formed, but adhesion between layers is weak and porosity is high
Solution Approach 1:
The patent applies parameter changes by heating the build plate or surrounding environment to a temperature close to the melting point of the filament material. This temperature parameter modification enables the deposited layers to naturally bond with the underlying layer through thermal diffusion, eliminating the need for additional energy beams and significantly improving interlayer adhesion while reducing porosity.
Solution Approach 2:
The invention implements self-service by allowing the heated build plate itself to provide the thermal energy required for layer bonding. The build plate's elevated temperature creates a self-sustaining thermal environment where each newly deposited layer automatically fuses with the previous layer without requiring external intervention from energy beams or additional heating mechanisms.
2Strength
If energy beams are used to melt layers, then interlayer bonding is improved, but process complexity increases
Solution Approach 1:
The patent extracts the melting function from a separate energy beam system and transfers it to the build plate itself. By removing the need for additional lasers or energy sources dedicated to melting, the invention simplifies the overall system architecture while maintaining effective interlayer bonding through the build plate's thermal field.
Solution Approach 2:
The build plate is given a dual function: it serves both as the support structure for depositing layers and as the heat source for melting and bonding those layers. This multi-functionality eliminates the need for separate melting mechanisms, reducing device complexity while achieving the desired bonding quality.
3Productivity
If filament material is deposited without preheating, then deposition speed is maintained, but chemical chain linkage between layers is insufficient
Solution Approach 1:
The patent applies preliminary action by preheating the build plate to a temperature close to the filament's melting point before deposition begins. This advance preparation creates a thermal environment that ensures immediate and effective chemical chain linkage between layers as they are deposited, maintaining both high deposition speed and strong interlayer bonding.
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 increases chemical chain linkage and adhesion in the Z-direction, reduces void space and porosity, and enhances the mechanical, thermal, and electrical properties of 3D printed objects.
Implementation Method 1
using at least a first energy beam from at least one energy source to selectively melt at least a portion of the first layer and/or the second layer
Implementation Method 2
enhancing diffusion and mixing between layers
Implementation Method 3
The at least one energy source is a laser and/or source of a hot fluid
Data Source
AI summary
The present disclosure provides methods for printing at least a portion of a three-dimensional (3D) object, comprising receiving, in computer memory, a model of the 3D object. Next, at least one filament material from a source of the at least one filament material may be directed towards a substrate that is configured to support the 3D object, thereby depositing a first layer corresponding to a portion of the 3D object adjacent to the substrate. A second layer corresponding to at least a portion of the 3D object may be deposited. The first and second layer may be deposited in accordance with the model of the 3D object. At least a first energy beam from at least one energy source may be used to selectively melt at least a portion of the first layer and/or the second layer, thereby forming at least a portion of the 3D object.