Optical Direction Modifiers in Additive Manufacturing Feedstock Lines
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Solution Overview
Problem
In 3D printing processes using photopolymers with reinforcing fibers, the opacity of fibers to curing energy prevents uniform curing due to shadowing effects, leading to incomplete or uneven curing of the resin.
Innovation Solution
Incorporating optical direction modifiers within the feedstock line, which redirect electromagnetic radiation to penetrate and cure the resin in shadowed regions, ensuring more even and thorough curing by scattering or dispersing the radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcing fibers are added to photopolymer feedstock material, then mechanical strength and structural integrity are improved, but uniform curing of the resin is worsened due to shadowing effects from opaque fibers
Solution Approach 1:
Optical direction modifiers act as intermediary elements between the curing energy source and the resin-fiber composite. These modifiers redirect electromagnetic radiation around the opaque fibers to reach shadowed resin regions, enabling uniform curing while maintaining fiber reinforcement. The modifiers serve as a mediating mechanism that resolves the conflict between fiber opacity and curing completeness.
2Productivity
If direct electromagnetic radiation is used to cure photopolymer resin, then curing speed is improved, but complete curing in shadowed regions is worsened due to fiber obstruction
Solution Approach 1:
The optical direction modifiers introduce a spatial redistribution of curing energy by redirecting radiation in multiple directions. Instead of direct line-of-sight curing that is blocked by fibers, the modifiers scatter and redirect energy around obstacles, adding dimensional complexity to the radiation path and enabling curing in previously inaccessible shadowed regions.
3Strength
If opaque reinforcing fibers are used in photopolymer feedstock, then structural reinforcement is improved, but electromagnetic radiation penetration is worsened
Solution Approach 1:
The optical direction modifiers are distributed locally throughout the feedstock material at specific concentrations and positions. This local distribution creates zones of radiation redirection throughout the composite structure, allowing energy to penetrate and cure resin in shadowed regions while maintaining the structural integrity provided by the fiber reinforcement network.
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
The solution allows for more efficient, uniform, and rapid curing of the resin within the feedstock line, even in areas obscured by reinforcing fibers, enhancing the additive manufacturing process, particularly in fused filament fabrication.
Implementation Method 1
Each of the optical direction modifiers is configured such that when electromagnetic radiation strikes the outer surface from a first direction, at least a portion of the electromagnetic radiation departs the outer surface in a second direction that is at an angle to the first direction
Implementation Method 2
the optical direction modifiers will redirect the electromagnetic radiation to disperse or scatter the electromagnetic radiation to indirectly reach regions of the resin
Implementation Method 3
When the polymer in the feedstock material is a photopolymer, a source of curing energy may be directed at the feedstock material, dispensed by the print head, to solidify the feedstock material
Data Source
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AI summary
A feedstock line (100) comprises elongate filaments (104), a resin (124), and optical direction modifiers (123). The resin (124) covers the elongate filaments (104). The optical direction modifiers (123) are covered by the resin (124) and are interspersed among the elongate filaments (104). Each of the optical direction modifiers (123) has an outer surface (184). Each of the optical direction modifiers (123) is configured such that when electromagnetic radiation (118) strikes the outer surface (184) from a first direction, at least a portion of the electromagnetic radiation (118) departs the outer surface (184) in a second direction that is at an angle to the first direction to irradiate, in the interior volume of the feedstock line (100), the resin (124) that, due at least in part to the elongate filaments (104), is not directly accessible to the electromagnetic radiation (118), incident on the exterior surface of the feedstock line.