3D Printed Mold Layer Composite for High Strength
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Solution Overview
Problem
Current 3D printing technologies face limitations in producing mechanically stable and resilient three-dimensional objects with high resolution, as they often require low-viscosity polymers, have limited service life for injection molds, and are not multi-material capable, leading to high material consumption and costs.
Innovation Solution
A method involving the use of a low-viscosity first material to create a negative mold layer, which is then filled with a higher viscosity second material that can be cross-linked using energy, allowing for the removal of the first material after solidification, enabling the production of objects with enhanced mechanical strength and multi-material capabilities within a single 3D printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If low-viscosity polymers are used for inkjet printing, then high printing resolution and surface quality are achieved, but the mechanical strength and durability of the printed objects are reduced
Solution Approach 1:
The patent uses composite materials by combining a first material (low-viscosity polymer for high-resolution printing) with a second material (higher-viscosity polymer or composite material for mechanical strength). The first material is printed at high resolution to create the geometric structure, then the second material is applied to reinforce and strengthen the printed object, achieving both high printing resolution and mechanical strength.
2Adaptability or versatility
If injection molds are produced using 3D printing, then production flexibility is improved, but the service life of the molds is limited due to high temperature exposure
Solution Approach 1:
The patent employs disposable or limited-life injection molds produced by 3D printing, accepting that the molds will have a limited service life (approximately 10 to 100 injection molding processes) due to high temperature exposure. This approach prioritizes production flexibility and rapid prototyping over long-term mold durability, allowing for easy replacement and reuse of molds.
3Device complexity
If single-material 3D printing is used, then process simplicity is maintained, but material consumption and production costs increase
Solution Approach 1:
The patent uses composite materials by combining a first material (low-viscosity polymer for high-resolution printing) with a second material (higher-viscosity polymer or composite material for mechanical strength). The first material is printed at high resolution to create the geometric structure, then the second material is applied to reinforce and strengthen the printed object, achieving both high printing resolution and mechanical strength.
4Strength
If high-viscosity materials are used for 3D printing, then mechanical strength and resilience are improved, but printing resolution and surface quality deteriorate
Solution Approach 1:
The patent segments the printing process into two distinct stages: first printing the geometric structure using low-viscosity material for high resolution, then applying and curing the second material to provide mechanical strength. This segmentation allows each material to be optimized for its specific function without compromising the other.
Solution Approach 2:
The patent uses composite materials by combining a first material (low-viscosity polymer for high-resolution printing) with a second material (higher-viscosity polymer or composite material for mechanical strength). The first material is printed at high resolution to create the geometric structure, then the second material is applied to reinforce and strengthen the printed object, achieving both high printing resolution and mechanical strength.
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 allows for the creation of objects with high mechanical and chemical resilience, improved surface quality, and reduced material costs by using different materials with varying properties, enabling efficient and precise production of complex geometries.
Implementation Method 1
liquid polymers which can be solidified by exposure to ultraviolet radiation are used as the first and second materials
Implementation Method 2
the main component of the molded article formed from the molded article layers is further crosslinked by a heat treatment and solidified
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
In a method for producing a three-dimensional mould and a three-dimensional shaped article (1) by means of layer-by-layer material application, geometric data for the shaped article (1), a carrier part (2) having a base surface (3) for accommodating the three-dimensional shaped article (1) and a consolidatable first and second material (4, 5) are provided. The second material (5) comprises at least one main component cross-linkable by treatment with energy and a thermally activatable, latent curing agent, by means of which a chemical cross-linking of the main component can be triggered by the action of heat. For forming a negative mould layer (12), the first material (4) is applied in accordance with geometric data to the base surface (3) and/or a consolidated material layer of the three-dimensional shaped article (1) present thereon in such a way that the negative mould layer (12) has at least one cavity (13) that has a negative mould of a material layer of the shaped article (1) to be produced. The negative mould layer (12) is consolidated. For formation of a shaped article layer (16), the cavity (13) is filled with the second material (5) and then the main component of the second material is partially cross-linked and is consolidated by treatment with energy. By means of a plane disposed at a distance from the base surface (3), protruding regions of the consolidated negative mould layer (12) and/or shaped article layer (16) are removed by material removal. The aforementioned steps are repeated at least once. The main component is further cross-linked by a heat treatment and is consolidated in such a way that the second material (5) has a higher strength than the consolidated first material (4) and the second material after the partial cross-linking. The negative mould layers (12) are removed from the shaped article (1).