3D Reverse Printing Method for High-Viscosity Materials
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Solution Overview
Problem
Existing 3D printing methods face challenges in utilizing materials with positive properties due to limitations in the range of materials that can be processed and susceptibility to errors, particularly with materials like concrete and reactive resin systems, which require intimate mixing and have high viscosities, making them difficult to print.
Innovation Solution
A method involving the selective application of a retarding agent via a print head to control the solidification of particulate build material, allowing for the use of standard materials with advantageous properties without the need for sintering, by starting or inhibiting the solidification reaction, and using a device with a coater and print head designed to handle self-hardening materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If standard materials with positive material properties (such as concrete, reactive resin systems) are used in conventional 3D printing methods, then material strength and structural integrity are improved, but the print head process component becomes susceptible to errors and cannot process these materials due to high viscosity and requirement for intimate mixing
Solution Approach 1:
The process is segmented into distinct functional zones: a mixing device where materials are intimately mixed, a coater that applies the mixture as layers, and a build platform where solidification occurs. This segmentation allows each component to be optimized for its specific function, enabling the use of materials like concrete that require mixing but would clog a traditional print head
Solution Approach 2:
The coater acts as an intermediary between the mixing device and the build platform. It receives the mixed material, applies it in controlled layers, and transfers it to the build platform where solidification occurs. This intermediary component enables the processing of high-viscosity materials that would otherwise be incompatible with direct extrusion printing
2Reliability
If reactive resin systems with high chain length prepolymers are used to minimize shrinkage and reduce health hazards, then material safety and dimensional stability are improved, but viscosity increases making the materials difficult or impossible to print
Solution Approach 1:
The materials are intimately mixed in the mixing device before being applied by the coater. This preliminary mixing ensures proper reaction between functional groups occurs in advance, and the mixture is then applied as a ready-to-solidify layer without requiring further mixing during the deposition process
Solution Approach 2:
The traditional mechanical extrusion system is replaced with a coater-based application system. Instead of forcing high-viscosity material through a print head, the coater applies the material as a layer, allowing high-viscosity reactive resin systems to be processed without clogging or dosing errors
3Manufacturing precision
If binder material is applied through the print head to selectively bond particulate material, then manufacturing precision is improved, but the range of processable materials is limited and materials with positive properties cannot be accessed
Solution Approach 1:
Instead of applying binder through the print head to selectively bond material, the invention inverts the approach: reactive material is applied as layers and selectively solidified by controlling where the solidification reaction occurs. The material itself becomes the binding agent through its solidification reaction, rather than requiring a separate binder applied by the deposition device
Solution Approach 2:
The particulate build material performs the binding function itself through its solidification reaction, rather than requiring an external binder applied by the coater. The material is self-binding as it transitions from liquid to solid state, eliminating the need for separate binder materials and expanding the range of usable materials
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
Enables the production of 3D models with good material properties cost-effectively and in a time-saving manner, without additional treatment steps like sintering, by applying build materials that solidify over time and using a retarding agent to control the solidification process.
Implementation Method 1
the solidification reaction of the build material has already started, starts or may be started by introducing energy upon the application of the build material, and a reaction-inhibiting or reaction-stopping liquid is selectively applied by the print head
Implementation Method 2
the solidification reaction of the build material has already started, starts or may be started by introducing energy upon the application of the build material
Data Source
AI summary
The present invention relates to a method and a device for producing three-dimensional models, wherein binding/bonding material is applied in layers to a building platform and media are selectively applied which delay or completely prevent the binding of the applied material.