Additively Manufactured Polymeric Components With Shape Memory

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Solution Overview

Problem

Current additive manufacturing techniques for polymers lack the ability to control polymer orientation effectively, limiting the creation of components that can exhibit significant shape changes in response to stimuli, such as thermal exposure, which restricts the complexity and functionality of three-dimensional structures.

Innovation Solution

The technique involves depositing polymeric materials at different rates and temperatures to create regions with varying degrees of polymer orientation, allowing the components to respond to shape change stimuli by exhibiting distinct dimensional changes, thereby enabling the formation of components with shape memory effects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If additive manufacturing techniques are used to deposit polymeric material, then three-dimensional structures can be formed, but the ability to control polymer orientation is limited

Engineering Contradiction:

Improvepolymer orientation controlVSAvoidadditive manufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies parameter changes by systematically varying deposition rate and temperature during additive manufacturing to control polymer orientation. By adjusting these parameters, the patent achieves different degrees of polymer orientation (from low to high) in different regions of the deposited material, thereby resolving the contradiction between manufacturing precision and process complexity.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If uniform deposition parameters are used, then manufacturing process is simple, but shape memory effects cannot be achieved

Engineering Contradiction:

Improveshape change response capabilityVSAvoiddeposition process simplicity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent applies local quality by creating regions with different polymer orientation characteristics within the same deposited structure. By varying deposition parameters locally (different rates and temperatures for different volumes), the patent enables different regions to exhibit different shape memory effects, thus achieving adaptability while managing manufacturing complexity through localized parameter adjustment.

Inventive Principle:

Principle #3Local quality

3Productivity

If high deposition rates are used, then productivity increases, but polymer orientation control decreases

Engineering Contradiction:

Improvedeposition rateVSAvoidpolymer orientation degree

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies dynamics by making the deposition parameters variable rather than fixed. The system dynamically adjusts deposition rate and temperature based on the desired polymer orientation for different regions. This allows the patent to achieve high productivity overall while maintaining precise polymer orientation control where needed by adapting parameters in real-time during the deposition process.

Inventive Principle:

Principle #15Dynamics

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 allows for the creation of additively manufactured components that can change dimensions, volume, configuration, or shape in response to stimuli, enhancing the complexity and functionality of three-dimensional structures produced through additive manufacturing.

Implementation Method 1

heated material, such as polymer, is extruded from a nozzle and cools to be added to the structure

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 2

The first volume and the second volume are configured to respond to a shape change stimulus by exhibiting a respective first change in dimension and a second change in dimension

Methodology Applied

Scientific EffectShape memory effect: Shape Memory Polymer

Data Source

PatentUS11833740B2Additively manufactured polymeric components

Publication Date: 2023.12.05 ROLLS ROYCE CORP

AI summary

An example technique may include depositing, on or adjacent a substrate, a first volume of a polymeric material using an additive manufacturing technique. The first volume of the polymeric material has a first degree of polymer orientation associated with a first deposition rate and a first temperature. The example technique may include depositing, on or adjacent the substrate or the first volume of material, at least one second volume of the polymeric material. The second volume of the polymeric material has a second degree of polymer orientation associated with a second deposition rate and a second temperature. The first volume and the second volume are configured to respond to a shape change stimulus by exhibiting a respective first change in dimension and a second change in dimension. The first change in dimension is different from the second change in dimension by a predetermined threshold.