Additive Manufacturing Device with Radiation Heating for Thermoplastic Components
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Solution Overview
Problem
Existing additive manufacturing methods for thermoplastic components result in inhomogeneous thermal load profiles, low mechanical load-bearing capacity, and poor surface quality due to strand-by-strand deposition, limiting their application to low mechanical load components such as prototypes and decorative items.
Innovation Solution
A device and method that uses a movable application device with a radiation source to heat and deposit thermoplastic material, allowing for higher fiber volume fractions and improved surface smoothing by heating the component surface above the melting temperature, reducing temperature gradients and embedding fiber reinforcement for enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If strand-by-strand deposition is used to manufacture thermoplastic components, then the manufacturing process is simple and applicable to prototypes, but the components exhibit inhomogeneous thermal load profiles and low mechanical load-bearing capacity
Solution Approach 1:
The patent replaces the mechanical extrusion-based strand deposition system with a radiation-based heating system that melts thermoplastic material directly at the deposition location. This substitution eliminates the thermal inhomogeneity caused by mechanical strand-by-strand accumulation, as the radiation source provides more uniform and controllable heating across the component surface, thereby improving thermal load profile homogeneity while maintaining manufacturing simplicity
Solution Approach 2:
The patent changes the thermal parameters by using radiation heating to achieve more uniform temperature distribution during the manufacturing process. By controlling the radiation intensity and duration, the system maintains more consistent material properties throughout the component, improving thermal load profile homogeneity and consequently enhancing mechanical load-bearing capacity
2Manufacturing precision
If conventional additive manufacturing is used for thermoplastic components, then the process is suitable for low mechanical load applications, but the components fail to meet technical surface requirements and have poor surface quality
Solution Approach 1:
The patent replaces conventional mechanical deposition with radiation-based melting and smoothing. The radiation source not only heats the material during deposition but also smooths the surface by remelting and redistributing the material, eliminating the ribbed or corrugated surface structure typical of strand-by-strand deposition. This results in superior surface quality that meets technical requirements while maintaining component strength
3Strength
If fiber reinforcement is added to improve mechanical properties, then the component strength increases, but the manufacturing process complexity increases and surface quality deteriorates
Solution Approach 1:
The patent uses radiation heating to melt and embed fiber reinforcement into the thermoplastic matrix more effectively than mechanical methods. The radiation source provides uniform heating that allows fibers to be properly integrated without disrupting surface quality, as the subsequent radiation-induced smoothing process remelts and levels the surface, eliminating the roughness that would otherwise result from fiber incorporation
Solution Approach 2:
The patent successfully integrates fiber reinforcement into the thermoplastic component using radiation-based manufacturing. The radiation heating process allows for proper fiber-matrix bonding and distribution, creating a composite material structure that enhances impact strength and mechanical properties while the radiation smoothing process maintains surface quality, resolving the contradiction between reinforcement and surface finish
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
The solution achieves components with increased impact strength, ductility, and surface quality, enabling the production of parts that can withstand higher mechanical loads and meet technical surface requirements, expanding the applicability of additive manufacturing beyond low-load applications.
Implementation Method 1
at least one radiation source (6), by means of which electromagnetic radiation is produced by means of which at least one partial area of the component (2) can be heated
Implementation Method 2
heating the component surface above the melting temperature
Data Source
AI summary
A device may be provided for additively manufacturing a component, comprising at least one component holder, which is designed to hold the component to be manufactured, and comprising at least one application device, which is designed to heat a thermoplastic material and to deposit it in a predeterminable amount, wherein the device also includes at least one radiation source, which is designed to produce electromagnetic radiation, by means of which at least one partial area of the component can be heated, and the device also includes at least one supply apparatus, which is designed to introduce a fiber reinforcement into the component, which fiber reinforcement includes or consists of an endless fiber. A method for additively manufacturing a component may also be provided.