Non-Laser 3D Printing with Inkjet Absorber for Cost Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current rapid prototyping methods, such as stereolithography and selective laser sintering, are costly and require complex equipment, limiting their accessibility and flexibility due to the need for expensive laser technology and specific optical systems, which also restrict the use of less expensive and flexible non-laser energy sources.
Innovation Solution
A process using non-laser sources of electromagnetic energy, specifically non-coherent and/or non-monochromatic radiation, with a selective absorber applied via an inkjet process to control heating in the sintering of pulverulent substrates, allowing for precise and cost-effective production of three-dimensional objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser technology is used for selective sintering, then manufacturing precision and speed are improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent introduces an absorber layer as an intermediary substance that selectively absorbs electromagnetic radiation and converts it to heat, mediating between the energy source and the pulverulent substrate. This allows non-laser energy sources to achieve precise localized heating through the absorber's selective placement, resolving the contradiction between precision and device complexity
Solution Approach 2:
The patent replaces the laser-based optical system with a non-laser electromagnetic radiation source combined with an absorber application system. This substitution eliminates the need for complex laser optics while maintaining sintering capability through the absorber's heat conversion function
2Reliability
If CO2 laser is used for sintering polymer powder, then sintering effectiveness is improved, but operating cost and maintenance cost increase
Solution Approach 1:
The patent employs a disposable or replaceable absorber layer that is applied fresh for each sintering operation or each layer. This consumable absorber allows the use of inexpensive non-laser energy sources, eliminating the need for expensive CO2 lasers while maintaining sintering effectiveness through the absorber's heat conversion capability
Solution Approach 2:
The patent changes the wavelength parameter of the energy source from the specific 10600 nm CO2 laser wavelength to a broader spectrum non-laser source, combined with an absorber that is tuned to absorb the new wavelength range. This parameter change enables the use of cheaper energy sources while maintaining sintering effectiveness
3Adaptability or versatility
If non-laser energy sources are used, then cost and flexibility are improved, but manufacturing precision deteriorates
Solution Approach 1:
The absorber layer serves as a precision-controlling intermediary that is selectively applied only to regions requiring sintering. This selective application allows non-laser energy sources to achieve precise localized heating, maintaining manufacturing precision while enabling the use of flexible and versatile non-laser energy sources
Solution Approach 2:
The patent applies the absorber with local quality - different regions receive different amounts or types of absorber based on their specific sintering requirements. This localized absorber application ensures precise heat generation only where needed, maintaining manufacturing precision while using flexible non-laser energy sources
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 enables the production of sintered prototypes with precision and speed comparable to laser sintering but at significantly lower costs, with greater flexibility in substrate selection and energy source usage, and allows for the incorporation of specific properties like conductivity during the printing process.
Implementation Method 1
electromagnetic energy, which is non-oriented and/or non-monochromatic and/or non-coherent... passed into an absorber, by way of which it is dissipated to the subregions of the substrate
Implementation Method 2
the beam spot may be smaller than the construction surface, and... the energy source may be of linear form and the introduction of energy may take place over the entire construction surface
Implementation Method 3
electromagnetic energy, which is non-oriented and/or non-monochromatic and/or non-coherent, of wavelength from 100 nm to 1 mm
Implementation Method 4
controlling a printing head with one or more nozzles for the purpose of applying a liquid or a suspension containing an absorber
Data Source
AI summary
The present invention relates to a process for the bonding of material for the production of three-dimensional objects by selective heating with electromagnetic energy which is either non-coherent and/or non-monochromatic and/or non-oriented, with a wavelength of from 100 nm to 1 mm.