Microwave Assisted Deposition for Rapid Thermoset Curing

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Solution Overview

Problem

Current 3D printing technologies face challenges in rapidly curing thermoset resins during the direct ink write process, limiting the ability to print complex geometries and requiring post-curing, which can be time-consuming and affect the quality of the final product.

Innovation Solution

The implementation of a microwave assisted deposition (MAD) system that uses a microwave resonance cavity to provide a localized microwave field for in-situ curing of thermoset resins as they are extruded, allowing for rapid curing of thermoset materials in microseconds to seconds, and enabling the 3D printing of complex geometries without the need for post-curing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional 3D printing methods are used to extrude thermoset resins, then the printing process can be performed, but the resins cannot be rapidly cured during deposition, requiring time-consuming post-curing

Engineering Contradiction:

Improvecuring speedVSAvoidpost-curing time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The microwave resonance cavity is positioned and configured in advance to receive and cure the thermoset resin immediately as it exits the deposition nozzle. The system is pre-aligned so that the resin passes through the resonant microwave field during extrusion, enabling curing to occur during the printing process itself rather than requiring separate post-curing steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces conventional thermal or UV curing mechanisms with microwave-based curing. The microwave resonance cavity generates electromagnetic fields at resonant frequencies that directly energize and cure the thermoset resin molecules, substituting traditional curing physics with electromagnetic resonance heating and curing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If thermoset resins are extruded without in-situ curing, then the printing process is simpler, but complex geometries cannot be maintained and quality is reduced

Engineering Contradiction:

Improvegeometry qualityVSAvoidcuring system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The microwave resonance cavity is positioned to create a localized electromagnetic field precisely at the deposition point where the thermoset resin exits the nozzle. This localized curing zone ensures that only the freshly deposited resin is cured immediately, maintaining complex geometric features and overhangs while avoiding the need to complicate the entire printing system.

Inventive Principle:

Principle #3Local quality

3Productivity

If a microwave resonance cavity is added to enable in-situ curing, then curing speed and printing capabilities are improved, but the device complexity increases

Engineering Contradiction:

Improveprinting efficiencyVSAvoidsystem structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The microwave resonance cavity serves multiple functions simultaneously: it acts as both the curing chamber and the microwave generation source, and its resonant properties enable efficient energy transfer to the resin. This multi-functionality reduces the need for separate curing lamps, heating elements, or additional control systems, thereby limiting the increase in overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 method enables the rapid and efficient 3D printing of thermoset resins and composites, including continuous fiber composites, allowing for the creation of complex part geometries with improved printing capabilities and eliminating the need for post-curing, thereby enhancing the scalability and quality of the printed objects.

Implementation Method 1

cause a microwave source to provide microwave energy into the microwave resonance cavity to emit a localized field at a point of deposition

Methodology Applied

Scientific EffectMicrowave radiation: Microwave Radiation

Implementation Method 2

provide microwave energy into the microwave resonance cavity to emit a localized field... to in-situ cure the thermoset

Methodology Applied

Scientific EffectDielectric heating: Dielectric Heating

Implementation Method 3

microwave resonance cavity... provide microwave energy into the microwave resonance cavity to emit a localized field

Methodology Applied

Scientific EffectResonance: Resonance

Implementation Method 4

in-situ cure the thermoset... produce a solidified thermoset object

Methodology Applied

Scientific EffectPolymerization:

Data Source

PatentUS12076926B2Systems and methods for three dimensional printing using microwave assisted deposition

Publication Date: 2024.09.03 RAVEN SPACE SYSTEMS INC

AI summary

Systems and methods for three-dimensional printing using microwave assisted deposition are disclosed herein. An example device includes a reservoir of carbonaceous nanocomposite thermoset, a microwave resonance cavity that cures the carbonaceous nanocomposite thermoset, and a sensor to measure the extrusion temperature of the resin when curing the carbonaceous nanocomposite thermoset at the point of deposition during extrusion-based 3D printing.