Multi-Material 3D Printer Using Powder Bed and Selective Binder Jetting
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Solution Overview
Problem
Current 3D printing technologies are limited in their ability to create objects with multiple materials and void spaces, as they typically use a single type of material for the entire object and lack the capability to embed different regions with various materials or create complex geometries with tortured exit pathways.
Innovation Solution
A 3D printer system utilizing multiple nozzle inkjet heads and powder coating systems to deposit and bind different materials on each layer, allowing for the creation of objects with multiple materials and void spaces by using fugitive materials that can be removed or filled with other materials, enabling the production of objects with properties similar to solid materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If FDM printers use multiple print heads with different filaments to create multi-material objects, then material diversity is improved, but printing speed deteriorates because the print head must trace every voxel at rates compatible with melting and extruding material
Solution Approach 1:
The patent replaces the mechanical extrusion system of FDM printers with a binder jetting system that uses inkjet technology to deposit binder material. This substitution allows for much faster printing speeds because inkjet deposition does not require the same mechanical constraints of melting and extruding material, while still achieving multi-material objects through selective binder application on different powder materials.
Solution Approach 2:
The patent changes the fundamental parameters of the printing process by using powder materials instead of filaments and binder jetting instead of extrusion. This allows the printing speed to be decoupled from material deposition rate, enabling faster printing while maintaining multi-material capability through selective binder placement on different powder types.
2Productivity
If binder jetting printers use a single powder material with selective binder application, then printing speed is improved, but material versatility deteriorates because the system cannot create objects with different regions of different materials
Solution Approach 1:
The patent segments the binder jetting system into multiple independent powder delivery systems, each capable of depositing a different powder material. This segmentation allows each material to be deposited in specific regions of the build plate, enabling multi-material objects while maintaining the fast printing speeds of binder jetting technology.
Solution Approach 2:
The patent implements local quality by allowing different powder materials to be deposited in different spatial regions of the build plate. Each region can receive the appropriate material type needed for that specific area of the object, enabling regional material variation while using a single binder jetting system that maintains high printing speed.
3Adaptability or versatility
If 3D printers create objects with multiple materials and void spaces, then design flexibility is improved, but device complexity deteriorates due to the need for multiple powder dispensers and coordination systems
Solution Approach 1:
The patent implements universality by designing a single build plate that can receive multiple different powder materials and a single binder jetting system that can selectively apply binder to different material regions. This multi-functional approach achieves multi-material and void space capability without requiring separate printing systems for each material type, thereby limiting the increase in device complexity.
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
Enables the creation of fully formed 3D objects with regions of different materials and void spaces, achieving properties similar to solid materials, such as alumina ceramic or steel alloy, while reducing material waste and increasing printing efficiency by minimizing excess powder removal and supporting structures.
Implementation Method 1
a binding powder is deposited thereon. An activating fluid is selectively dispensed over the layers by a slidably arranged inkjet print head to activate the binding powder, such that the activated binding powder binds the build material into a cross-section of a to be fabricated object
Implementation Method 2
The binder is cured, and the excess powder is removed
Data Source
Figure 1
Figure 2~8
Figure 9
AI summary
A layer of a first powder is dispensed in a layer over a build plate. Binder is then selectively applied to hold portions of the layer of first powder together. Unbound first powder is then removed. A second powder is then dispensed in a layer over the build plate and portions of the bound first powder above the build plate. Binder is then selectively applied to hold portions of the second powder together. Unbound second powder is then removed. A third or more different powders can be similarly dispensed and bound to complete a multi-material layer. The process is then be repeated on a next subsequent layer. A curing radiation source can accelerate binding of powder together. Voids can be formed in portions of the layers by dispensing a fugitive material in portions of each multi-material layer. Mechanisms for implementing the printing process are also disclosed.