3D-Printed Passive Components With In-Situ Electrical Feedback Control
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Solution Overview
Problem
Current additive manufacturing techniques for passive electronic components lack precision in controlling electrical properties such as resistance, capacitance, and inductance, leading to inaccuracies and material waste, which are not suitable for industries requiring high accuracy like high-speed communications.
Innovation Solution
Implementing a feedback loop system that continuously monitors the electrical properties during manufacturing, adjusting the material deposition rate based on real-time measurements to achieve precise control over the electrical properties of passive components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If additive manufacturing is used to rapidly produce passive electronic components, then manufacturing speed and material efficiency are improved, but manufacturing precision of electrical properties deteriorates
Solution Approach 1:
The patent implements a feedback control system where a sensor continuously measures the electrical property (resistance, capacitance, or inductance) of the passive component during additive manufacturing. The measured value is compared to a target value, and the material deposition rate is dynamically adjusted based on the difference. This closed-loop feedback mechanism enables rapid manufacturing while maintaining high electrical property accuracy by compensating for variations in real-time.
2Manufacturing precision
If material deposition is controlled to achieve exact electrical properties, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system adds a sensor, processor, and control mechanism to the additive manufacturing device. The sensor measures the electrical property during deposition, the processor compares the measured value to the target value and calculates the necessary adjustment, and the control mechanism modifies the material deposition rate accordingly. This feedback-controlled system achieves precise electrical properties through dynamic adjustment rather than relying solely on pre-calculated geometry.
Data Source
AI summary
Systems and methods of additively manufacturing passive electronic components are provided. An additive manufacturing device may deposit a material to create a passive electronic component. A sensor may continuously measure an electrical property of the passive electronic component across two electrical contacts as the material is deposited during manufacturing. The sensor may transmit the measured electrical property to a processor whereby the processor may adjust a material deposition rate of the additive manufacturing device. The continuous measurement of the electrical property and adjustment of the material deposition rate as the passive electronic component is produced allows for passive electronic components to be manufactured to a high degree of accuracy of the electrical property.