Multi-Head Solid Freeform Fabrication for Composite Material Versatility

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Solution Overview

Problem

Conventional solid freeform fabrication techniques have limited throughput and material versatility when using multiple modeling materials, resulting in inferior material properties compared to standard engineering polymers.

Innovation Solution

A system with multiple dispensing heads that operates in two modes: one for single material fabrication and another for using two or more materials, allowing for simultaneous or segmented deposition of different materials to create composite materials with varied properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional solid freeform fabrication techniques use multiple modeling materials, then material versatility is improved, but throughput deteriorates

Engineering Contradiction:

Improvematerial versatilityVSAvoidthroughput

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent divides the fabrication process into separate dispensing heads, each dedicated to a specific modeling material. This segmentation allows multiple materials to be dispensed simultaneously without interfering with each other, thereby maintaining high throughput while achieving material versatility. Each dispensing head operates independently, enabling parallel processing of different materials during the same build cycle.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fabrication system is designed with multiple dispensing heads that can handle different modeling materials, creating a multi-functional system. This universal approach allows the same equipment to fabricate objects using various materials with different properties, achieving both material versatility and maintained productivity through integrated simultaneous dispensing.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If conventional techniques use multiple modeling materials, then material variety is improved, but material properties deteriorate

Engineering Contradiction:

Improvematerial varietyVSAvoidmaterial properties

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent enables different regions of the fabricated object to use different modeling materials with optimized properties for specific applications. Each dispensing head is configured to deposit its material in predetermined locations, allowing local optimization of material properties such as flexibility, hardness, or elasticity in different parts of the same object, thereby maintaining high material property standards while achieving variety.

Inventive Principle:

Principle #3Local quality

3Productivity

If multiple dispensing heads operate simultaneously, then fabrication speed is improved, but system complexity increases

Engineering Contradiction:

Improvefabrication speedVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines multiple dispensing heads into a single integrated fabrication system that operates simultaneously. By merging the functionality of multiple material dispensing operations into one coordinated system, the patent achieves high fabrication speed while managing complexity through unified control architecture and synchronized operation of all dispensing heads during the same build cycle.

Inventive Principle:

Principle #5Merging (Combining)

4Stability of the object's composition

If conventional techniques use two-part curable material from downward jetting, then material mixing is prevented, but fabrication flexibility is reduced

Engineering Contradiction:

Improvematerial separationVSAvoidfabrication flexibility

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

Instead of jetting material from a downward direction as in conventional techniques, the patent inverts the approach by using dispensing heads that deposit material in a controlled manner from above or at optimized angles. This inversion allows for better material placement flexibility and composition control while preventing unwanted mixing through precise positioning and independent operation of each dispensing head.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentEP2664443B1Solid freeform fabrication using a plurality of modeling materials

Publication Date: 2021.08.25 STRATASYS LTD

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Figure 1b~1d
Figure 2a~2b

AI summary

The present invention relates to a method of solid freeform fabrication of an object, the object having a plurality of regions, the method comprising (a) inputting data pertaining to shapes of the object and each of the plurality of regions (b) for at least one region: (i) defining a plurality of sub-areas within said region and attributing a property to each sub-area; (ii) for each sub-area, selecting a modeling material and/or a modeling material combination according to said attributed property of said sub-area, thereby selecting a plurality of modeling materials or modeling material combinations; and (c) dispensing said selected modeling materials or modeling material combinations in a layerwise manner according said input data and said sub-areas so as to form the three-dimensional object.