High-Roughness Mesh Platform for Inverted 3D Print Adhesion
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Solution Overview
Problem
Current methods for forming artificial organs and scaffolds for tissue engineering involve time-consuming chemical modification of platforms, leading to inconsistencies and low adhesion, which results in inaccurate and defective 3D models, especially for fine biological structures.
Innovation Solution
A 3D printing apparatus and method using a platform with a base and mesh that enhances adhesion by having a higher adhesion strength between photocurable ink and the mesh compared to an oxygen permeable membrane, and a print layer with increased surface roughness to promote stable model formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If chemical modification of the platform is used to increase adhesion, then adhesion strength is improved, but formation time increases and consistency deteriorates
Solution Approach 1:
The patent extracts the adhesion function from the platform itself and transfers it to a separate mesh layer. The mesh layer with high surface roughness is coupled to the platform, providing the adhesion function without requiring chemical modification of the platform. This allows the platform to be reused without time-consuming re-modification while maintaining strong adhesion.
Solution Approach 2:
The mesh layer acts as an intermediary between the platform and the photocurable ink. It provides the adhesion function through its high surface roughness, eliminating the need for direct chemical modification of the platform. This intermediary layer can be easily replaced or cleaned, reducing formation time for subsequent printing operations.
2Strength
If chemical modification of the platform is used to increase adhesion, then adhesion strength is improved, but manufacturing consistency deteriorates
Solution Approach 1:
The adhesion function is extracted from the platform and embodied in a separate mesh layer with controlled high surface roughness. This mesh layer can be manufactured with precise, consistent properties and coupled to the platform, eliminating variability from chemical modification processes.
Solution Approach 2:
The patent changes the surface roughness parameter of the mesh layer to be significantly higher than the platform surface. This physical parameter change provides consistent adhesion through mechanical interlocking rather than variable chemical modification, improving manufacturing precision and repeatability.
3Ease of manufacture
If a smooth platform surface is used, then ease of manufacture is improved, but adhesion strength deteriorates
Solution Approach 1:
The system is segmented into two distinct layers: a smooth platform that is easy to manufacture and a separate mesh layer with high surface roughness that provides adhesion. This segmentation allows each component to be optimized independently - the platform for ease of manufacture and the mesh for adhesion performance.
Solution Approach 2:
The mesh layer is localized to the specific region where adhesion is needed, while the rest of the platform maintains its smooth surface for ease of manufacture. This local application of high surface roughness only where required allows the platform to be easily manufactured while providing strong adhesion at the print interface.
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 reduces formation time, increases adhesion and accuracy, and produces defect-free, large, and heavy 3D models, particularly for complex structures like small blood vessels and lung sub-bronchi structures.
Implementation Method 1
a bottom of the vat comprises an oxygen permeable membrane
Implementation Method 2
a mesh of a first side of the base, wherein an adhesion strength between a photocurable ink to the mesh is greater than an adhesion strength of the photocurable ink to an oxygen permeable membrane
Implementation Method 3
a vat configured to store a photocurable ink
Data Source
AI summary
A platform form an apparatus for printing a 3D model comprises a base and a print layer. The base has a first side where the first side of the base has a first surface roughness thereon. The print layer is coupled first side of the base and includes a surface. The surface of the print layer is distal from the base and has a second surface roughness which is greater than the first surface roughness so as to promote adhesion of the 3D model being printed on the platform.