Optical Waveguide Core for Uniform Resin Curing in Shadowed Feedstock

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Solution Overview

Problem

Existing 3D printing processes using opaque reinforcing fibers in photopolymer feedstock materials face challenges as these fibers cast shadows, preventing uniform curing of the photopolymer due to shielding from direct electromagnetic radiation.

Innovation Solution

Incorporating optical direction modifiers, such as optical direction-modifying particles or partial-length optical waveguides, into the feedstock line to redirect electromagnetic radiation and ensure even curing of the resin by scattering it into shadowed regions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If opaque reinforcing fibers are used in photopolymer feedstock material, then mechanical strength and structural integrity are improved, but uniform curing of the photopolymer deteriorates due to shadow casting

Engineering Contradiction:

Improvemechanical strengthVSAvoidcuring uniformity

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent introduces a dual-curing system where a first curing mechanism (e.g., chemical curing or alternative energy source) acts as an intermediary to cure regions shadowed by opaque fibers, while a second curing mechanism (e.g., electromagnetic radiation) cures exposed regions. This intermediary approach allows both opaque fibers and uniform curing to coexist.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the curing parameters by using multiple curing mechanisms with different penetration characteristics. The first curing mechanism targets shadowed regions while the second targets exposed regions, allowing the curing process to adapt to the heterogeneous structure created by opaque fibers.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If direct electromagnetic radiation is applied to cure the photopolymer, then curing speed is improved, but curing completeness deteriorates in shadowed regions

Engineering Contradiction:

Improvecuring speedVSAvoidcuring completeness

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent segments the curing process into two distinct phases: first curing shadowed regions using a penetrating mechanism, then curing exposed regions using direct electromagnetic radiation. This segmentation ensures both completeness and speed by addressing different regions with appropriate methods.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent performs preliminary curing of shadowed regions before applying direct electromagnetic radiation to exposed regions. This preliminary action ensures that regions that would otherwise remain uncured are treated first, allowing subsequent fast curing of exposed areas without compromising overall completeness.

Inventive Principle:

Principle #10Preliminary action

3Speed

If photopolymer is used as feedstock material, then rapid curing capability is improved, but cureability in shadowed regions deteriorates

Engineering Contradiction:

Improvecuring capabilityVSAvoidshadow region cureability

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The patent introduces a first curing mechanism as an intermediary that can penetrate opaque fibers to cure shadowed photopolymer regions, enabling rapid curing throughout the entire feedstock line including areas not directly accessible to electromagnetic radiation.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Facilitates more efficient, thorough, and rapid curing of the resin within the feedstock line, particularly suitable for additive manufacturing processes like 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

Methodology Applied

Scientific EffectScattering: Scattering

Implementation Method 2

an optical waveguide comprising an optical core and a cladding, the cladding covering a portion of the optical core, wherein a refractive index of the cladding is smaller than that of the optical core

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Data Source

PatentEP3702134B1An optical waveguide comprising an optical core and method of modifying an optical core to create an optical waveguide

Publication Date: 2026.01.07 THE BOEING CO

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AI summary

An optical waveguide (108) comprises an optical core (146), comprising a first end face (148), a second end face (150), opposite the first end face (148), and a peripheral surface (152), extending between the first end face (148) and the second end face (150). The optical waveguide (108) is configured such that when electromagnetic radiation (118) enters the optical core (146) via at least one of the first end face (148), the second end face (150), or the peripheral surface (152), at least a portion of the electromagnetic radiation exits the optical core (146) via the peripheral surface (152).