Radiant Barrier Baffles for Uniform 3D Printing Heating

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Solution Overview

Problem

3D printing technologies face issues with non-uniform heating and fusing due to multi-scattering of radiant energy, leading to variable irradiance and unintentional heating of build materials, especially when a fusing agent is not present, resulting in inconsistent layer formation and part defects.

Innovation Solution

The implementation of a radiant barrier with energy-absorbing baffles, such as thin plates or sheets with dark or flat colors, is introduced between the lamp and reflector to absorb and control radiant energy, reducing multi-scattering and ensuring more uniform heating across the build material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a radiant heater is used to heat build material, then heating capability is improved, but non-uniform heating and multi-scattering occur leading to variable irradiance

Engineering Contradiction:

Improveheating capabilityVSAvoidheating uniformity

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

A radiant barrier is introduced as an intermediary component between the radiant heater and the build material. This barrier intercepts and redistributes radiant energy, preventing direct multi-scattering paths while maintaining heating capability. The barrier acts as a mediator that transforms the heating pattern from non-uniform to more uniform distribution across the build material surface.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The radiant barrier is designed with specific local properties including dark or flat colors to maximize radiant energy absorption and reflection characteristics. By optimizing the local optical properties of the barrier surface, the system achieves better control over radiant energy distribution, converting harmful multi-scattering into useful uniform heating patterns.

Inventive Principle:

Principle #3Local quality

2Area of stationary object

If radiant energy is allowed to scatter freely, then heating coverage is improved, but unintentional heating of build materials occurs leading to inconsistent layer formation

Engineering Contradiction:

Improveheating coverageVSAvoidlayer formation consistency

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The radiant barrier serves as a controlling intermediary that manages radiant energy distribution. It allows adequate heating coverage by reflecting and redirecting energy across the build area while preventing unwanted multi-scattering paths that cause inconsistent heating. The barrier maintains reliable and consistent layer formation by regulating the thermal environment.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system converts the potentially harmful effect of radiant energy multi-scattering into a beneficial uniform heating pattern. By introducing the radiant barrier, the scattered energy that would otherwise cause inconsistent heating is redirected to create more uniform thermal distribution, turning a problem into a solution.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Device complexity

If no radiant barrier is used, then device complexity is reduced, but thermal uniformity and material properties deteriorate

Engineering Contradiction:

Improveheater structure simplicityVSAvoiddimensional accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

A radiant barrier is introduced as a relatively simple intermediary component between the heater and build material. This addition maintains thermal uniformity and dimensional accuracy by controlling radiant energy paths without requiring complex heating systems. The barrier provides a straightforward solution to achieve consistent thermal fields and reliable material properties.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution provides improved thermal uniformity, enhanced material properties, increased dimensional accuracy, reduced part defects, and better color accuracy, making the printing process more economical and desirable by minimizing the effects of multi-scattering and ensuring consistent layer formation.

Implementation Method 1

a radiant barrier with energy-absorbing baffles, such as thin plates or sheets with dark or flat colors, is introduced between the lamp and reflector to absorb and control radiant energy

Methodology Applied

Scientific EffectAbsorption (EM radiation): Absorption (EM radiation)

Implementation Method 2

The heater radiates energy to the deposited build material to bond/fuse those portions on which the fusing agent has been printed

Methodology Applied

Scientific EffectThermal Radiation: Thermal Radiation

Data Source

PatentUS11858215B2Build material heaters with baffles

Publication Date: 2024.01.02 PERIDOT PRINT LLC

AI summary

In some examples, a printer includes a feed mechanism to distribute a build material on a platform and a heater. The heater includes a lamp, a reflector, and a radiant energy absorbing baffle located between the lamp and the reflector. The lamp and the reflector are to direct radiant energy toward the platform, and the radiant energy is to heat the build material.