Pseudoplastic 3D Printing Without Support Structures
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Solution Overview
Problem
Current 3D printing technologies face challenges in manufacturing large, complex structures like cantilever-like objects without support structures, as the thin layers used are mechanically weak and prone to deformation, requiring extensive manual labor and materials, and are time-consuming.
Innovation Solution
The method employs pseudoplastic materials that exhibit shear-thinning properties, allowing them to flow under agitation and solidify quickly, enabling the creation of complex structures like cantilever-like objects without internal support structures by using a system with a pump, extrusion unit, and UV curing, which reduces viscosity under pressure for deposition and regains strength after extrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thin layers are used for additive manufacturing, then manufacturing precision is improved, but mechanical strength deteriorates causing layers to be mechanically weak and prone to deformation
Solution Approach 1:
The patent applies parameter changes by utilizing the shear-thinning property of pseudoplastic materials, where viscosity changes dramatically under different shear conditions. During extrusion, high shear rate reduces viscosity for flowability, while after deposition, low shear rate increases viscosity for structural strength. This parameter change resolves the contradiction between thin layer precision and mechanical strength.
Solution Approach 2:
The patent implements dynamics by using materials whose rheological properties dynamically adapt to processing conditions. The pseudoplastic material transitions from a fluid state during extrusion to a solid-like state after deposition, enabling thin layers to be deposited with high precision while maintaining mechanical strength without requiring support structures.
2Stability of the object's composition
If support structures are added to prevent warping, then stability is improved, but device complexity increases and manual labor is required
Solution Approach 1:
The patent applies self-service by using pseudoplastic materials that automatically provide their own support during manufacturing. The material's shear-thinning property enables it to be extruded in thin layers that self-support without requiring additional support structures, eliminating the need for manual intervention to prevent warping or collapse.
Solution Approach 2:
The patent uses parameter changes in material viscosity to achieve structural stability without support structures. The pseudoplastic material exhibits high viscosity after deposition, allowing thin layers to maintain their shape and provide self-support, thereby eliminating the need for complex support structures and manual labor.
3Ease of manufacture
If conventional materials are used, then ease of manufacture is maintained, but productivity deteriorates due to long manufacturing time
Solution Approach 1:
The patent applies parameter changes by using pseudoplastic materials whose viscosity dynamically responds to shear rate. This enables rapid extrusion of thin layers that maintain shape fidelity, significantly reducing manufacturing time while keeping the process simple and easy to implement with minor equipment modifications.
Solution Approach 2:
The patent implements dynamics through materials that adapt their rheological properties in real-time during processing. The pseudoplastic material flows easily during extrusion but quickly gains structural integrity after deposition, enabling high-speed manufacturing without sacrificing ease of manufacture or requiring complex support systems.
4Loss of substance
If large objects are manufactured as shells, then material cost is reduced, but reliability deteriorates due to warping and deformation
Solution Approach 1:
The patent applies parameter changes by using pseudoplastic materials that maintain high viscosity after deposition, enabling thin-walled hollow structures to achieve sufficient structural reliability without warping or deformation. This reduces material consumption while maintaining the integrity of large-scale shell structures.
Solution Approach 2:
The patent implements dynamics through pseudoplastic materials that transition from a flowable state during extrusion to a structurally sound state after deposition. This dynamic property change allows large objects to be manufactured as thin-walled shells with adequate reliability, eliminating the need for excessive material usage while preventing warping and deformation.
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 allows for the rapid and stable production of large, hollow, and complex 3D structures without conventional support structures, reducing material costs and manufacturing time, and achieving high bond strength between layers.
Implementation Method 1
The pseudoplastic material has a first viscosity at atmospheric pressure and a second viscosity at a pressure exceeding atmospheric pressure. The second viscosity is lower than the first viscosity.
Implementation Method 2
a source of UV radiation configured to cure or harden the extruded pseudoplastic material
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3D
AI summary
The current three-dimensional object manufacturing technique relies on the deposition of a pseudoplastic material in gel aggregate state. The gel flows through a deposition nozzle because the applied agitation and pressure shears the bonds and induces a breakdown in the material elasticity. The elasticity recovers immediately after leaving the nozzle, and the gel solidifies to maintain its shape and strength.