3D Printed Porous Objects via Dual Binding Agent Deposition
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Solution Overview
Problem
Current additive manufacturing systems face challenges in producing complex geometries and efficient heat transfer components, such as heat pipes and vapor chambers, due to limitations in creating structures with regions of varying porosity, which are essential for enhanced heat exchanger performance.
Innovation Solution
An additive manufacturing system that uses a first and second binding agent to create 3D printed objects with regions of differing porosity by depositing copper powder and selectively applying copper nitrate and silver nanoparticle ink, allowing for the formation of porous wicking structures and non-porous, watertight walls within a single printing cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single binding agent is used in additive manufacturing, then the manufacturing process is simple, but the object cannot have regions of differing porosity
Solution Approach 1:
The patent applies local quality by using different binding agents (first binding agent and second binding agent) in different regions of the same 3D object. The first binding agent creates porous regions while the second binding agent creates non-porous regions, allowing each region to have the specific porosity characteristics needed for its function. This resolves the contradiction by enabling porosity variation without requiring multiple separate printing processes.
Solution Approach 2:
The patent uses composite materials by combining multiple binding agents with different properties within a single additive manufacturing process. The first binding agent (organic binder) and second binding agent (inorganic binder) work together to create a composite structure with spatially varying porosity. This allows the object to have both porous and non-porous regions in a single manufactured component.
2Reliability
If complex geometries with varying porosity are required, then heat exchanger performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple functions into a single manufacturing process by combining the creation of porous regions, non-porous regions, and complex geometries all in one additive manufacturing cycle. The controller coordinates the deposition of build material and selective application of different binding agents simultaneously, eliminating the need for separate printing, assembly, and post-processing steps that would otherwise be required.
Solution Approach 2:
The patent applies parameter changes by varying the binding agent selection, powder size distribution, binder quantity, and sintering cycles to achieve different porosity levels in different regions. These parameter adjustments enable the creation of optimized heat exchanger geometries with tailored porosity profiles without requiring complex multi-step manufacturing processes.
3Manufacturing precision
If multiple parts are assembled to create varying porosity, then porosity control is precise, but assembly complexity and time increase
Solution Approach 1:
The patent merges the creation of multiple porosity regions into a single additive manufacturing process, eliminating the need to assemble multiple separate parts. The controller manages the selective deposition of binding agents during one continuous printing cycle, creating all required porous and non-porous regions in place. This resolves the contradiction by maintaining precise porosity control while eliminating assembly steps and reducing production cycle time.
4Reliability
If powder size and binder quantity are varied to tune porosity, then capillary pressure and heat transfer are improved, but process complexity increases
Solution Approach 1:
The patent systematically varies parameters including powder size distribution, binder quantity, and sintering cycles to achieve desired porosity levels in different regions. The controller manages these parameter changes automatically, selecting appropriate powder sizes and binder amounts for each region based on the target porosity requirements. This enables precise control of capillary pressure and heat transfer properties through parameter optimization rather than complex mechanical adjustments.
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
Enables the creation of customized heat exchanger geometries with improved capillary pressure, capacity, and boiling performance by tuning porosity through varying powder size, binder quantity, and sintering cycles, facilitating the production of complex components without assembly of multiple parts.
Implementation Method 1
heating the build material to a temperature between a melting temperature of the particles in the second binding agent and a melting temperature of the first binding agent
Implementation Method 2
the particles in the second binding agent melt and fuse between holes in the powder build material
Implementation Method 3
depositing a powder build material, and then depositing a first binding agent on portions of the build material
Implementation Method 4
A porous region may act as a filter while a non-porous region may provide a water-tight and/or air tight body
Data Source
AI summary
In one example in accordance with the present disclosure, an additive manufacturing system is described. The additive manufacturing system includes an additive manufacturing device to form a three-dimensional (3D) printed object with regions of differing porosity. The additive manufacturing system also includes a controller to form the 3D printed object. Specifically, by controlling ejection of a first binding agent onto a porous region and a non-porous region of the 3D printed object and controlling ejection of a second binding agent onto the non-porous region of the 3D printed object.