3D Printer Pressure-Assisted Fluid Extraction
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Solution Overview
Problem
Current 3D printing technologies face challenges in achieving high speed and fine resolution simultaneously, with inkjet printing offering high resolution but low deposition rates, and jetted binder printing providing high deposition rates but limited resolution.
Innovation Solution
A 3D printing system that combines inkjet printing with a pressure-assisted fluid extraction method, using a receiver device with a substrate and an inkjet print head to deposit an ink with a particulate material and liquid vehicle, followed by a removal system that uses a pressure differential to dry the printed layer, allowing for rapid layer formation and high packing density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If inkjet printing is used to deposit material, then fine resolution is achieved, but deposition rate is low
Solution Approach 1:
The process is divided into two distinct stages: first, rapid deposition of particulate material and liquid vehicle using jetted material printing to achieve high deposition rates; second, selective inkjet printing of binder material onto the deposited layers to achieve fine resolution bonding. This segmentation allows each process to optimize for its strength without being constrained by the other's limitations.
2Productivity
If jetted binder printing is used to deposit material, then high deposition rate is achieved, but resolution is limited
Solution Approach 1:
The liquid vehicle acts as an intermediary carrier that enables rapid deposition of particulate material without requiring immediate binder application. This intermediary layer allows the system to achieve high deposition rates during material placement, then use selective inkjet printing of binder as a mediator to achieve fine resolution bonding in a subsequent step, effectively decoupling the deposition rate and resolution requirements.
3Quantity of substance
If liquid vehicle is removed from printed layer, then packing density is improved, but processing time increases
Solution Approach 1:
The system applies preliminary action by rapidly depositing thick layers of particulate material and liquid vehicle using jetted material printing before binder application. This preliminary high-rate deposition establishes the bulk structure and packing density requirements, allowing subsequent binder jetting to occur on already-dense layers rather than requiring slow, sequential layer-by-layer construction, thereby reducing overall processing time while maintaining high packing density.
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 preservation of fine resolution while significantly improving printing speed, achieving high deposition rates and fine resolution, which is not typically possible with either inkjet or jetted binder printing alone.
Implementation Method 1
an ink including a suspension of a particulate material in a liquid vehicle
Implementation Method 2
a removal system configured to use a pressure differential to remove a portion of the liquid vehicle from the printed layer
Data Source
AI summary
A three-dimensional (3D) printer and method are provided, including a substrate, a liquid deposition device configured to deposit a liquid dispersion including a suspension of a particulate material in a liquid vehicle, the liquid vehicle including a solvent but devoid of a binder material, onto the substrate to form a non-patterned layer on the substrate, a solvent removal device configured to remove at least a portion of the solvent from the liquid vehicle from the non-patterned layer to form a dried non-patterned layer, and a liquid binder print head configured to deposit a liquid binder onto the dried non-patterned layer to form a printed pattern on the dried non-patterned layer.