Multi-Material 3D Printing with In-Situ Cleaning and Micro-SL
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Solution Overview
Problem
Current 3D additive manufacturing techniques are limited in the types of materials they can use and the architectures of structures they can create, particularly in producing multi-material objects with micro-scale features, which face challenges such as contamination, limited material choices, and difficulties in achieving high resolution and detail.
Innovation Solution
The development of multi-material 3D additive manufacturing systems with an in-situ cleaning system and a scanning optical projection micro-sterolithography (micro-SL) system that includes a Y axis jethead with cleaning solution dispensers and brushes, an X axis cartridge with fluidic channel systems, and an optical printing head system, allowing for the fabrication of multi-material objects with micro-scale features and improved resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multi-material 3D additive manufacturing is used to create objects with micro-scale features, then the resolution and detail are improved, but contamination between materials occurs
Solution Approach 1:
The cleaning system performs preliminary cleaning actions between material deposits by dispensing cleaning solution onto the build platform and using brushes to mechanically remove residual materials before the next material is deposited, preventing contamination while maintaining micro-scale resolution
Solution Approach 2:
A cleaning solution is introduced as an intermediary substance between different printing materials. The cleaning solution is dispensed through fluidic channels and applied via brushes to remove residual materials from the build platform, preventing cross-contamination while allowing high-resolution multi-material printing
2Reliability
If cleaning systems are added to remove contamination, then material purity is improved, but device complexity increases
Solution Approach 1:
The cleaning system is merged with the printing system by integrating cleaning solution dispensers, fluidic channels, and brushes directly into the printing head assembly. This combination allows cleaning functions to be performed within the existing printing mechanism, reducing overall system complexity while maintaining material purity
Solution Approach 2:
The printing head assembly is designed with multi-functionality, serving both as a material deposition system and a cleaning system. The same mechanical structure that deposits materials also dispenses cleaning solution and positions brushes, eliminating the need for separate cleaning mechanisms and reducing device complexity
3Manufacturing precision
If high resolution scanning optical projection is used to create micro-scale features, then manufacturing precision is improved, but printing speed decreases
Solution Approach 1:
The scanning optical projection system operates continuously to scan and cure photosensitive material across the entire build platform area without stopping. The galvanometer mirrors continuously deflect the light beam across X and Y axes, maintaining continuous curing action that improves printing speed while preserving micro-scale resolution through precise optical control
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 multi-material 3D objects with micro-scale features, reducing contamination and improving resolution, speed, and detail, suitable for applications like tissue engineering, microfluidics, and ultralight-ultra strong materials.
Implementation Method 1
a cleaning solution dispenser; wherein the cleaning solution dispenser is coupled to the body portion such that when in operation cleaning solution that is dispensed from the cleaning solution dispenser contacts the brush
Implementation Method 2
a fluidic channel system, wherein the fluidic channel system is configured to receive cleaning solution that is dispensed from the cleaning solution dispenser and is further configured to remove used cleaning solution from the fluidic channel system
Implementation Method 3
directing a light wave from a light source across the two mirrors and onto the portions of photosensitive printing material having the projected image to cure the printing material to form a layer in a 3D object
Data Source
AI summary
Provided herein are 3D printing systems including, but not limited to, 3D printing systems that can, in some aspects, be configured to print multi-materials and/or 3D structures having micro-scale features. In some aspects, the 3D printing system can include a jethead, wherein the jethead can include a body portion, one or more printing material dispensers that are each coupled to one or more feedstock material reservoirs and the body portion, and at least one cleaning unit configured to clean a printed object, a printing platform, a component of an x axis cartridge, or any combination thereof. Also provided herein are scanning projection optical micro-sterolithography systems that can be configured to allow for printing micro-scale features in large scale 3D objects.