3D Structure Manufacturing via Porous Sheet Lamination
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Solution Overview
Problem
Existing three-dimensional modeling methods face challenges in efficiently manufacturing structures using functional materials, particularly for practical applications like artificial organs, due to limitations in material selection, formation time, and the ability to create complex microstructures with sufficient porosity and mechanical strength.
Innovation Solution
A method involving the lamination of porous sheets with functional liquids, where a second porous sheet is bonded onto a first sheet containing a functional liquid, and a second functional liquid is introduced through the sheets to form a three-dimensional structure, allowing for the use of various materials like metals, ceramics, and biodegradables, and enabling the creation of structures with high porosity and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If extrusion methods are used to supply materials from one nozzle, then material selection is limited, but formation time becomes excessively long
Solution Approach 1:
The patent divides the material supply system into multiple nozzles (first nozzle and second nozzle) that can operate simultaneously. Each nozzle supplies different materials (solvent and solid content) separately, enabling parallel processing and significantly reducing formation time while expanding material selection scope
Solution Approach 2:
The patent changes the discharge parameters by using multiple nozzles with different discharge characteristics. The first nozzle discharges solvent at a higher speed while the second nozzle discharges solid content, creating optimal conditions for forming both simple and complex three-dimensional structures with various materials
2Speed
If inkjet methods use low viscosity liquid materials, then discharge speed increases, but solid concentration must be suppressed to about 10% resulting in thin film thickness
Solution Approach 1:
The patent segments the inkjet discharge process into two separate nozzles: one for solvent and one for solid content. This allows the solvent to be discharged at high speed for rapid coverage while the solid content can be discharged separately without being constrained by the 10% concentration limit, enabling formation of thicker films with higher solid concentrations
Solution Approach 2:
The patent changes the discharge parameters by controlling the timing, speed, and amount of solvent versus solid content discharge. By adjusting these parameters independently through separate nozzles, the system achieves both high discharge speed and high solid concentration, forming films with thickness exceeding conventional limits
3Adaptability or versatility
If two kinds of ink are used for forming three-dimensional structure and support member, then formation time increases due to replacement of ink heads
Solution Approach 1:
The patent segments the inkjet system into multiple fixed nozzles (first nozzle for solvent, second nozzle for solid content) that are positioned to discharge simultaneously or in coordinated sequence. This eliminates the need for ink head replacement between different material types, maintaining high productivity while enabling functional differentiation
Solution Approach 2:
The patent creates a multi-functional inkjet system where the first and second nozzles work together as an integrated unit. The system can form both the three-dimensional structure and support members without requiring physical replacement of components, achieving universality in handling different material types while maintaining high formation speed
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 enables the rapid formation of three-dimensional structures with desired porosity and mechanical properties, suitable for biological applications such as artificial organ scaffolds, by allowing the use of a wide range of materials and reducing formation time through the use of inkjet methods and surface treatments.
Implementation Method 1
porous sheets are laminated... containing a first functional liquid... causing a second functional liquid to be contained
Data Source
AI summary
A manufacturing method of a three-dimensional structure includes (a) placing a second porous sheet on top of a first porous sheet that has a predetermined external shape and at least part of which contains a first functional liquid, (b) bonding at least a range surrounded by a predetermined shape of the second porous sheet onto the first porous sheet, (c) processing the second porous sheet in the predetermined shape, and (d) after step (b), causing a second functional liquid to be contained in at least part of the range of the second porous sheet so that the first functional liquid and the second functional liquid are brought into contact through the first porous sheet and the second porous sheet.