Resin Bubble Removal by Preheating in Additive Manufacturing
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Solution Overview
Problem
Bubbles formed during additive manufacturing with viscous materials, such as resins, lead to stress concentration points, premature object failure, and aesthetic issues, particularly in transparent objects like dental aligners.
Innovation Solution
A system and method that utilizes heating elements to decrease the viscosity and surface tension of curable materials, causing bubbles to rise and burst at the surface, and employs physical processes like thermophoresis to move bubbles to higher-temperature portions for removal, without the need for material-specific chemicals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heating elements are used to decrease viscosity and surface tension to remove bubbles, then bubble removal effectiveness is improved, but energy consumption increases
Solution Approach 1:
The heating element applies heat to the curable material before the energy curing process to pre-heat the material, reduce its viscosity and surface tension, and facilitate bubble removal during the deposition process, rather than attempting to remove bubbles after curing
Solution Approach 2:
The system changes the temperature parameter of the curable material by applying heat, which directly affects the viscosity and surface tension parameters, enabling bubbles to rise and burst at the surface more effectively
2Reliability
If material-specific chemicals are used to remove bubbles, then bubble removal effectiveness is improved, but material compatibility and safety are worsened due to toxicity
Solution Approach 1:
The invention replaces chemical methods with a physical method (heating) to achieve bubble removal, eliminating the need for chemical additives that could be toxic or incompatible with certain curable materials
Solution Approach 2:
The curable material itself is utilized to remove bubbles through thermophoresis, where bubbles naturally migrate toward higher-temperature portions of the material and burst at the surface, without requiring external chemical agents
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
Improves mechanical properties and reduces material waste by effectively removing bubbles during the manufacturing process, ensuring consistent quality and reducing the need for chemical treatments that can be toxic or incompatible with certain materials.
Implementation Method 1
heating elements to decrease the viscosity and surface tension of curable materials
Implementation Method 2
heating elements to decrease the viscosity and surface tension of curable materials
Implementation Method 3
employs physical processes like thermophoresis to move bubbles to higher-temperature portions for removal
Data Source
AI summary
Methods and systems for additive manufacturing are provided. In some embodiments, a method includes depositing a curable material on a substrate. The method can also include directing heat toward the curable material to remove one or more bubbles present in the curable material. The method can also include outputting energy toward the curable material on the substrate to form an object portion on a build platform according to an additive manufacturing process.