3D Curing of 2D Printed Objects via Partial UV Treatment
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Solution Overview
Problem
Three-dimensional printing systems face challenges in creating structurally sound and deformity-free three-dimensional objects from flat substrates, particularly in footwear and apparel, where reshaping with existing methods often results in shear stresses and visible deformities due to inadequate curing and material properties.
Innovation Solution
A method involving a printing system that partially cures ink layers with ultraviolet radiation on a flat substrate before reshaping, followed by full curing in a nonplanar configuration, utilizing factors like curvature, thickness, and flexibility to avoid structural deformities, and employing a combination of printing techniques to achieve desired structural properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the substrate is reshaped into a nonplanar configuration after printing, then the three-dimensional structure is achieved, but shear stresses and visible deformities occur due to inadequate curing
Solution Approach 1:
The patent applies preliminary partial curing to the printed material before reshaping the substrate into its final three-dimensional configuration. This preliminary action strengthens the material sufficiently to prevent deformities during subsequent reshaping operations, while leaving it flexible enough to conform to the desired shape.
Solution Approach 2:
The patent utilizes parameter changes by controlling the degree of curing at different stages. The material transitions from a fully uncured state (flexible) to a partially cured state (intermediate flexibility and strength) during reshaping, and finally to a fully cured state (rigid and stable) after the three-dimensional configuration is achieved.
2Strength
If the ink layers are fully cured before reshaping, then structural integrity is maximized, but the material becomes too rigid to conform to nonplanar configurations
Solution Approach 1:
The patent applies preliminary partial curing to provide initial structural support while maintaining flexibility. This intermediate curing state allows the material to be strong enough to hold its shape during reshaping but flexible enough to conform to complex three-dimensional configurations.
Solution Approach 2:
The patent applies partial curing rather than full curing at the intermediate stage. This partial action provides sufficient strength to prevent deformities during reshaping while leaving the material with enough flexibility to adapt to the final three-dimensional configuration. Full curing is then applied after reshaping to maximize structural integrity.
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 method ensures the creation of three-dimensional objects with enhanced structural integrity and absence of shear stresses or visible deformities, maintaining desired shapes and properties throughout the transformation from a flat to a nonplanar configuration.
Implementation Method 1
The ink layers are selectively cured by a radiation source, such as an ultraviolet light source
Data Source
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AI summary
A printing system is used to selectively print a layer material on a surface that is initially in a planar or two-dimensional shape. After the layer material is printed onto the surface, it is exposed to an amount of radiation from a radiation source and partially cured. Several layer materials may be placed on top of one another and are also partially cured. The flat surface may be reshaped into a nonplanar or three-dimensional shape, and the layer materials are again exposed to an amount of radiation and fully cured.