Binder Jetting Micropixelation for High-Precision Parts
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Solution Overview
Problem
Current solid freeform fabrication (SFF) techniques, such as binder jetting, face limitations in precision and speed due to imperfections in producing green parts, often resulting in components that fail to meet high precision application tolerances, especially regarding surface finish.
Innovation Solution
The use of a combination of particulate materials and photocurable resin materials in SFF devices, allowing for improved material deposition and imaging techniques, including bulk deposition, in situ infusion, and micropixelation, to produce high-resolution composite layers with enhanced properties and interchangeability of material components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If binder jetting is used for SFF, then material deposition is simplified, but manufacturing precision deteriorates due to imperfections in producing green parts
Solution Approach 1:
The patent applies preliminary action by infusing the green part with binder material before the debinding process. This pre-binder infusion strengthens the green part structure, reducing defects and improving surface finish before the critical debinding stage, thereby resolving the precision issue while maintaining ease of manufacture
Solution Approach 2:
The patent changes the physical and chemical parameters of the binder material by using different binder types, concentrations, and infusion pressures. These parameter adjustments optimize the green part strength and surface quality, enabling high precision while keeping the binder jetting process simple
2Productivity
If traditional SFF methods are used, then production speed is maintained, but manufacturing precision deteriorates due to inability to meet high precision tolerances
Solution Approach 1:
The patent performs preliminary densification and binder infusion on each layer before moving to the next layer. This ensures that each layer achieves optimal density and dimensional accuracy during the build process itself, rather than requiring post-processing, thus maintaining production speed while improving precision
Solution Approach 2:
The patent replaces traditional mechanical sintering methods with a combination of binder infusion and controlled debinding. This substitution allows for better dimensional control and precision while maintaining or improving production speed, as the chemical binder process is more controllable than thermal sintering
3Ease of manufacture
If green parts are produced with standard binder jetting, then production cost is reduced, but reliability deteriorates due to defects that fail to meet tolerances
Solution Approach 1:
The patent applies preliminary binder infusion and densification to green parts before debinding. This prevents defects such as cracking, warping, and surface imperfections that would cause component failure, thereby improving reliability while keeping the overall process cost-effective by avoiding expensive post-processing and rework
Solution Approach 2:
The patent provides beforehand cushioning by infusing binder material into the green part structure prior to debinding. This creates a protective binder network that cushions against stress and defects during the critical debinding process, ensuring components meet tolerance requirements and improving reliability without significantly increasing cost
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 enables the production of high-density, high-precision parts with improved surface quality and internal adhesion, overcoming the limitations of traditional SFF methods by achieving near-full density and increased production speed.
Implementation Method 1
The build material is composed of a particulate material and a photocurable resin material
Data Source
AI summary
A fabrication device includes a build surface to receive layers of material for production of a 3-dimensional solid representation of a digital model and an imaging component to bind respective portions of the build material into cross sections representative of portions of data contained in the digital model. The imaging component may be a programmable planar light source utilizing a micropixelation system and refractive pixel shifting mechanism, or other imaging system. The device may include a system for controlling the density of the printed part. The object may be a powder composite component using any of a variety of powder materials or a plastic component. The object may be further post-processed to produce a high precision metal or ceramic component.