Phase Changing Material Support for Complex 3D Printing
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Solution Overview
Problem
Current 3D printing techniques face challenges in fabricating complex geometries like cylindrical, toroidal, and spherical scaffolds, requiring specialized equipment and being time-consuming, and often involve the use of support materials that need to be washed away after printing.
Innovation Solution
The method involves using a temporarily phase-changed yield stress material as both the printing medium and support, allowing for the creation of complex structures without the need for additional support materials by applying focused energy to displace the first material with a second material, enabling the printing of intricate designs without the limitations of surface tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional 3D printing uses solid support material printed layer by layer, then the printed structure can be supported during fabrication, but the support material must be washed away after printing which increases loss of time and loss of substance
Solution Approach 1:
The patent changes the physical state parameter of the support material from solid to liquid by applying focused energy (laser, microwave, or radio frequency). This allows the support material to be in a liquid state during printing to provide structural support, then transition to a removable state after printing by reversing the phase change, eliminating the need for time-consuming support removal processes
Solution Approach 2:
The patent utilizes phase transitions of the support material between solid and liquid states. During printing, focused energy maintains the support material in a liquid state for proper deposition and support. After printing, the energy is removed and the material transitions back to solid state, allowing easy removal without washing, thus resolving the contradiction between providing structural support and avoiding time-consuming support removal
2Reliability
If conventional 3D printing uses solid support material, then structural support is provided during printing, but the process becomes more complex and time-consuming
Solution Approach 1:
The patent dynamically changes the physical state parameter of the support material during the printing process. By applying focused energy selectively to specific regions, the support material transitions from solid to liquid only where needed, simplifying the overall process compared to printing and removing solid support structures while maintaining necessary structural support during fabrication
3Reliability
If conventional 3D printing prints support material simultaneously with the printed structure, then structural support is provided, but manufacturing time increases and productivity decreases
Solution Approach 1:
The patent uses phase transitions to enable the support material to be liquid during printing (providing support) and then easily removable after printing. This eliminates the need for separate support removal operations, directly improving productivity by reducing total manufacturing time while maintaining structural support during the printing process
Solution Approach 2:
By changing the physical state parameter of the support material through focused energy application, the patent enables a more efficient printing process where support material is deposited in liquid form and then removed through phase reversal rather than mechanical washing, thereby increasing manufacturing efficiency and productivity
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 reduces manufacturing time and costs by eliminating the need for support material removal and allows for the creation of finely detailed structures with arbitrary geometries, including complex tissues and organs, by using materials like silicones and hydrogels that remain fluid or self-heal, enabling precise cell culture scaffolds and vascular networks.
Implementation Method 1
causing a phase change in a region of the first material by applying focused energy to the region using a focused energy source
Data Source
AI summary
A method or apparatus for three-dimensionally printing. The method may comprise causing a phase change in a region of the first material by applying focused energy to the region using a focused energy source, and displacing the first material with a second material. The apparatus may comprise a container configured to hold a first material, a focused energy source configured to cause a phase change in a region of the first material by applying focused energy to the region, and an injector configured to displace the first material with a second material. The first material may comprise a yield stress material, which is a material exhibiting Herschel-Bulkley behavior. The yield stress material may comprise a soft granular gel. The second material may comprise one or more cells.