Microwave Nanoparticle Support Removal for 3D Printing
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Solution Overview
Problem
Current methods for removing support material from three-dimensional printed objects are time-consuming and inefficient, especially as the size of printed objects increases, limiting production speed in high-volume production.
Innovation Solution
A system and method utilizing a platen, ejector heads, and a microwave radiator to selectively apply support material with and without nanoparticles, where microwave energy causes the support material to change phase, allowing for efficient removal of support material without damaging the printed object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional methods (water soaking, chemical soaking, convection heating) are used to remove support material, then the support material can be removed, but the process is time-consuming and inefficient
Solution Approach 1:
The patent changes the physical-chemical parameters of the support material by incorporating nanoparticles (such as iron oxide, aluminum, or titanium dioxide) that have high dielectric loss or magnetic loss properties. This modification enables the support material to rapidly convert microwave energy into heat, causing it to melt quickly and facilitate fast removal, thereby resolving the contradiction between productivity and time consumption.
Solution Approach 2:
The patent utilizes phase transition of the support material from solid to liquid state through microwave-induced heating. The nanoparticles absorb microwave energy and convert it to heat, causing the support material to undergo rapid phase transition and melt, enabling quick removal without damaging the printed object. This phase transition mechanism dramatically reduces support removal time while maintaining high productivity.
2Loss of time
If microwave energy is applied to remove support material, then removal speed increases, but there is risk of damaging the printed object
Solution Approach 1:
The patent applies local quality by creating support material with different compositions in different locations. Interior support material contains nanoparticles for rapid microwave heating and quick melting, while exterior support material is nanoparticle-free or has lower nanoparticle concentration to protect the printed object from excessive heat. This spatial differentiation of material properties enables fast support removal while protecting the object from damage.
3Productivity
If multiple objects are stacked in three-dimensions to increase production volume, then production capacity increases, but substantial amounts of support material must be removed
Solution Approach 1:
The patent modifies the support material parameters by incorporating nanoparticles that enable rapid microwave heating. This allows the large quantities of support material required for multi-object stacking to be quickly melted and removed through microwave irradiation, converting what would be a time-consuming removal process into an efficient operation that maintains high productivity despite increased support material volume.
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
Facilitates rapid and efficient removal of support material by using nanoparticles to quickly convert microwave energy into heat, melting interior support before exterior support, thus protecting the object and enabling faster production processes.
Implementation Method 1
operating a microwave radiator with the at least one controller to irradiate the object and the support for the object with microwave energy
Implementation Method 2
The nanoparticles can have a dielectric loss factor that is greater than a dielectric loss factor for the support material, which is greater than a dielectric loss factor of the object material
Implementation Method 3
The nanoparticles can consist essentially of ferromagnetic material
Implementation Method 4
enable the portions of the support containing the nanoparticles to begin to change phase from a solid to a liquid before the portions of the support formed with the second material alone begin to change phase from a solid to a liquid
Implementation Method 5
melting interior support before exterior support
Data Source
AI summary
A method of manufacturing a three-dimensional object facilitates the removal of support material from the object. The method includes forming at least a portion of a support for the object with support material containing nanoparticles of a material that readily converts microwave energy into heat. The object and support are moved to a position opposite a microwave radiator and the microwave radiator is operated to begin a change of the phase of the portion of the support material containing the nanoparticles before beginning a change of the phase of a portion of the support made from the support material alone. A controller either monitors the expiration of a predetermined time period or a temperature of the object to determine when the microwave radiator operation is terminated.