3D Printed Shield for Thermal Uniformity in Build Chamber
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Solution Overview
Problem
3D printing technologies face challenges in maintaining dimensional accuracy due to thermal non-uniformities in the build chamber, causing variations in cooling rates and subsequent contractions or expansions of printed objects, which can lead to inaccuracies.
Innovation Solution
A method where a shield is printed simultaneously with the objects during the same build process, designed to reduce heat dissipation and converge cooling rates across the build chamber, using thermal behavior data to model the shield's geometry and placement, thereby stabilizing the cooling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If materials are used for 3D printing build process, then objects can be printed, but dimensional accuracy deteriorates due to contractions or expansions during fusing and cooling processes
Solution Approach 1:
The patent applies parameter changes by modifying the cooling rate parameter through the use of a shield structure. The shield changes the thermal parameters of the build chamber, creating a more uniform cooling environment that compensates for material contraction and expansion, thereby improving dimensional accuracy without requiring changes to the material itself.
Solution Approach 2:
The shield acts as an intermediary element between the build chamber environment and the printed objects. This intermediary structure mediates the thermal environment by reducing heat loss to the surroundings, thereby stabilizing the cooling process and improving dimensional accuracy of the printed objects.
2Productivity
If different cooling rates are used for different positions in build chamber, then printing speed can be optimized, but dimensional accuracy deteriorates due to varying contractions
Solution Approach 1:
The shield uniformly modifies the cooling rate parameter across all positions in the build chamber. By changing the thermal environment through the shield, the patent achieves more consistent cooling rates throughout the chamber, thereby improving dimensional accuracy while maintaining printing productivity.
Solution Approach 2:
The shield creates a more homogeneous thermal environment in the build chamber by reducing heat loss uniformly across different positions. This homogenization of the cooling conditions ensures that all printed objects experience similar cooling rates, improving dimensional accuracy regardless of their position in the chamber.
3Manufacturing precision
If shield is printed to reduce heat dissipation, then cooling rate uniformity improves, but device complexity increases
Solution Approach 1:
The shield is implemented as a relatively simple structural element that can be printed using the same 3D printing process. This thin-walled structure effectively reduces heat loss and improves cooling uniformity without requiring complex mechanical systems, active control mechanisms, or additional hardware components.
Solution Approach 2:
The shield is printed as part of the build chamber structure itself, utilizing the existing 3D printing capability. This self-service approach means the shield is created using the same equipment and process already in place, avoiding the need for separate manufacturing processes or additional complex systems to create the thermal management structure.
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 improves the dimensional accuracy of printed objects by uniformizing cooling rates, reducing thermal losses, and minimizing positional and geometrical variations within the build chamber.
Implementation Method 1
a shield to shield the one or more printed objects in the build chamber to reduce heat dissipation to an outside of the build chamber
Implementation Method 2
different regions of the build chamber may have cooling rates which converge to each other
Data Source
AI summary
An apparatus comprises a processor and a machine-readable storage medium storing machine-readable instructions executable by the processor. The machine-readable instructions comprise instructions to cause the processor to create 3D print data including data defining one or more objects to be printed in a build chamber of a 3D printer and data defining, in addition to the one or more objects, a shield to be printed to shield the one or more printed objects in the build chamber to reduce heat dissipation to an outside of the build chamber. The shield is designed depending on a thermal behavior of the build chamber and/or depending on a thermal behavior of the one or more objects to be printed.