Temperature Differential Control for Resin Air Bubble Reduction
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Solution Overview
Problem
Additive manufacturing techniques, such as stereolithography, often result in defects like air bubbles in three-dimensional objects due to excess air being entrapped in the resin, leading to wasted materials and time, particularly for one-off or customized objects.
Innovation Solution
A method and apparatus that control a temperature differential between a first temperature and a second temperature in the manufacturing process by heating the liquid resin to a higher temperature to dissolve air and then cooling it to a lower temperature before deposition, allowing for increased air absorption and reducing air bubble entrapment in the final product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If additive manufacturing is used to create one-off or customized objects, then manufacturing time and cost are reduced, but air bubbles are entrapped in the material leading to defects
Solution Approach 1:
The resin is pre-heated before the additive manufacturing process to reduce air entrapment. This preliminary thermal treatment modifies the resin's physical properties to prevent bubble formation during subsequent deposition, addressing the quality issue before manufacturing begins
Solution Approach 2:
The temperature of the resin is changed from ambient to elevated levels during the manufacturing process. This parameter modification affects the resin's viscosity and air solubility, preventing air bubble entrapment while maintaining the benefits of additive manufacturing
2Manufacturing precision
If heating liquid resin to high temperature, then air dissolution increases, but energy consumption increases
Solution Approach 1:
The resin is heated continuously throughout the additive manufacturing process rather than intermittently. This continuous thermal treatment maintains optimal temperature for air dissolution throughout material deposition, ensuring consistent quality without repeated heating cycles
Solution Approach 2:
The resin undergoes thermal phase changes from ambient temperature to elevated temperature states. These controlled phase transitions modify the resin's physical properties to optimize air dissolution while managing energy input through predictable thermal behavior
3Manufacturing precision
If cooling liquid resin to lower temperature, then air absorption increases, but transfer time increases
Solution Approach 1:
The resin is pre-cooled in the reservoir before being transferred to the build area. This preliminary cooling occurs during the material preparation phase rather than during active deposition, minimizing impact on manufacturing throughput while maximizing air absorption benefits
Solution Approach 2:
A temperature gradient is established as an intermediary mechanism between the heated resin source and the build area. This gradient allows progressive cooling during transfer, enabling air absorption without requiring complete temperature equilibration that would delay production
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 effectively minimizes air bubble defects in three-dimensional objects, enhancing the quality and reducing material waste and production time, especially for customized or one-off items.
Implementation Method 1
heating a volume of liquid in a reservoir to the first temperature
Implementation Method 2
controlling a transfer time for transferring the portion of the volume of liquid to the object coater head to allow the portion of the volume of liquid to be cooled to the second temperature
Implementation Method 3
A temperature differential between the first temperature and the second temperature is controllable to increase the ability of the volume of liquid to dissolve air prior to being deposited from the object coater head
Data Source
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AI summary
The present application relates to an apparatus for generating a three-dimensional object. The apparatus may be used for controlling a temperature differential between a first temperature and a second temperature in the generation of the object. The apparatus includes a reservoir comprising a volume of liquid. The apparatus further includes an object coater head configured to deposit a portion of the volume of liquid on one of a support and an already formed part of the object. The apparatus further includes a heating source configured to heat the liquid in the reservoir to a first temperature and a device configured to control the transfer of a portion of the volume of liquid from the reservoir to the object coater head so that the portion of the volume of liquid is at a second temperature when the portion of the volume of liquid is deposited from the object coater head.