Multi-Material 3D Printing via Selective Deposition and Curing
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Solution Overview
Problem
Selective curing in three-dimensional printing is limited by its ability to use only a single material, restricting the diversity of properties and structures that can be fabricated.
Innovation Solution
A two-step printing process combining selective deposition and selective curing, where a thin layer of liquid photopolymer is selectively deposited on a transparent substrate and then cured according to a predetermined pattern, allowing for distinct body and support regions to be created using different materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If selective curing is used to fabricate objects, then printing speed is improved, but material diversity is limited to a single material
Solution Approach 1:
The patent combines selective deposition and selective curing into a unified printing system. The system uses an inkjet deposition head to deposit multiple liquid materials (body material and support material) onto a substrate, followed by UV curing to solidify the deposited layers. This merging allows the system to achieve both multi-material capability and high printing speed that were previously mutually exclusive.
Solution Approach 2:
The patent employs composite material strategy by using different liquid materials with distinct properties for different functional regions. Body material provides structural integrity while support material enables easy removal after printing. The system can deposit multiple material types in the same printing process, creating composite structures with diverse properties within a single object.
2Adaptability or versatility
If selective deposition is used to achieve multi-material fabrication, then material diversity is improved, but printing speed decreases compared to selective curing
Solution Approach 1:
The patent replaces the traditional mechanical layer-by-layer deposition process with a UV curing mechanism. Instead of mechanically building up each layer slowly, the system deposits liquid material and then uses UV light to rapidly cure and solidify it. This substitution of the solidification mechanism dramatically increases printing speed while preserving multi-material capability.
Solution Approach 2:
The system performs preliminary deposition of multiple liquid materials in quick succession before curing. The inkjet deposition head can rapidly deposit different material types onto the substrate, and then the UV curing step quickly solidifies all deposited materials. This preliminary action approach allows material diversity to be achieved without the slow sequential building process.
3Ease of manufacture
If traditional dispensing methods are used, then material dispensing is simple, but accuracy is insufficient for complex structures
Solution Approach 1:
The patent uses digital image data to control the deposition process. A digital model of the object is sliced into cross-sectional layers, and each layer's geometry is used to generate deposition patterns for the inkjet head. This digital copying approach ensures high precision in material placement while maintaining the simplicity of automated dispensing processes.
Solution Approach 2:
The system employs feedback control through computer-controlled deposition heads that precisely follow digital geometric data. The deposition process is guided by calculated layer geometries from 3D models, ensuring accurate material placement. The system can adjust deposition parameters based on the specific geometric requirements of each layer, maintaining both simplicity and precision.
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 fabrication of complex objects with diverse properties and structures by using multiple materials, improving printing efficiency and enabling the use of materials that cannot be accurately dispensed via traditional methods, such as slurries with solid particles.
Implementation Method 1
a thin layer of liquid photopolymer is selectively deposited according to a predetermined cross section pattern on a transparent surface or substrate... the thin photopolymer layer is selectively cured according to the predetermined cross section pattern, by irradiation via a high-resolution image of curing light passed through the transparent substrate
Data Source
AI summary
An apparatus for preparing a two-dimensional layer of a three-dimensional object during three-dimensional printing of the object. The apparatus may include a controller; a transparent substrate for receiving a deposited layer of liquid materials on an upper surface thereof; a selective deposition unit that deposits at least one liquid body material and a liquid support material different from the at least one liquid body material, on the transparent substrate according to signals received from the controller; and a selective curing unit that selectively solidifies, by curing irradiation, a portion of the deposited layer of liquid body materials on the transparent substrate according to signals received from the controller, such that some of the liquid body material remains uncured.