Sacrificial 3D Structure Blocks Solvent Migration in Binder Jetting
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Solution Overview
Problem
During the curing process of 3D printing, solvents from binder agents migrate and cause part quality defects and a reduction in mechanical properties of 3D objects by excess solvent accumulation, leading to dimensional accuracy issues.
Innovation Solution
A computing system modifies print data to include a 3D structure within the build volume that inhibits solvent migration by selectively ejecting a binder agent or permeability modifier agent, such as water and ethanol, to create a sacrificial element that blocks solvent flow, thereby protecting the 3D objects from solvent interference during curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If binder agent is applied to generate 3D objects through selective solidification, then 3D objects are formed successfully, but solvents from the binder agent migrate during curing and cause part quality defects and dimensional accuracy issues
Solution Approach 1:
A sacrificial 3D structure is introduced as an intermediary element between the build objects and the solvent flow path. This structure absorbs migrating solvents during curing, preventing them from reaching and degrading the 3D objects. The sacrificial structure is later removed, having served its protective function.
Solution Approach 2:
The harmful solvent migration is redirected toward the sacrificial 3D structure instead of the valuable 3D objects. By positioning the sacrificial structure in the solvent flow path, the harmful solvents are absorbed and concentrated in a disposable element, converting the harmful migration effect into a beneficial protection mechanism for the final objects.
2Strength
If solvents are allowed to migrate during curing, then binder agent functions properly, but mechanical properties of 3D objects are reduced due to excess solvent accumulation
Solution Approach 1:
The sacrificial 3D structure serves as a mediator that intercepts and absorbs excess solvents during the curing process. This prevents solvent accumulation in the 3D objects, thereby preserving their mechanical properties while still allowing the binder agent to function properly in forming the objects.
Solution Approach 2:
The harmful solvents are extracted from the system by directing them into the sacrificial 3D structure. This extraction prevents the solvents from accumulating in the 3D objects, thus maintaining the mechanical integrity of the final products.
3Manufacturing precision
If a 3D structure is added to block solvent migration, then part quality is improved, but device complexity and build volume requirements increase
Solution Approach 1:
The sacrificial 3D structure is positioned only in the specific regions where solvent migration occurs, rather than throughout the entire build volume. This localized approach blocks solvent paths where needed while minimizing the overall addition to build volume and system complexity.
Solution Approach 2:
The sacrificial structure utilizes the vertical dimension by extending from the build plate upward through the build volume, creating a three-dimensional barrier that intercepts solvent flow without requiring additional horizontal space. This dimensional approach efficiently blocks solvent migration paths while minimizing footprint.
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 3D structure effectively prevents solvent migration, enhancing the mechanical properties and dimensional accuracy of the printed objects by isolating them from solvent flow, thus improving part quality.
Implementation Method 1
selective application of a binder agent to particulate build material in the build volume
Implementation Method 2
the 3D structure to inhibit migration of solvents from the binder agent during a curing operation
Implementation Method 3
migration of solvents of the binder agent used in the generation of the plurality of 3D objects
Data Source
AI summary
A computing device comprising a processor is disclosed herein. The processor is to access print data of a virtual build volume including a plurality of 3D objects to be generated through a selective application of a binder agent by a 3D printer. The processor is further to modify the print data to include a 3D structure at a location within the build volume to protect a 3D object from migrating solvents of the binder agent during a curing operation.