Additive Manufacturing With Shear-Rate Material Tuning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional additive manufacturing processes lack the ability to customize the material properties of 3D printed objects, resulting in inferior strength compared to injection molding.
Innovation Solution
An additive manufacturing system with a shear rate tuning mechanism and temperature control mechanism to adjust molecular orientation, crystallinity, and filler distribution in 3D objects, using a feeder, heaters, and a nozzle to control the material properties during the printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional additive manufacturing processes are used, then the manufacturing process is simple, but the material properties cannot be customized and the strength is inferior to injection molding
Solution Approach 1:
The patent implements dynamic control of shear rate and temperature during the extrusion process. The shear rate is varied by adjusting the rotation speed of the extrusion screw and the diameter of the extrusion die, while temperature is controlled through heating zones. These dynamic adjustments enable real-time modification of material properties such as crystallinity and molecular orientation, allowing customization without requiring complex post-processing or multiple material types.
Solution Approach 2:
The patent changes physical parameters (shear rate and temperature) during the manufacturing process to control material properties. By adjusting shear rate through extrusion speed and die geometry, and temperature through controlled heating, the system modifies crystallinity, molecular orientation, and filler distribution. This parameter-based control enables a single additive manufacturing system to produce materials with diverse properties, eliminating the need for multiple specialized systems.
2Strength
If layering technique is used in conventional additive manufacturing, then the manufacturing process is straightforward, but the strength of fabricated products is inferior to injection molding
Solution Approach 1:
The patent applies local quality control by independently adjusting shear rate and temperature at different locations and times during the extrusion process. The extrusion die geometry and heating zones can be configured to create spatially varying material properties within the extruded filament. This allows different regions of the printed object to have optimized local properties (e.g., higher crystallinity in load-bearing areas) while maintaining the simplicity of the layering process.
Solution Approach 2:
The patent performs preliminary action by controlling molecular orientation and crystallinity during the extrusion process before the material is deposited. By pre-aligning polymer chains and establishing desired crystalline structures in the extruded filament, the system ensures high strength properties are built into the material itself during extrusion, rather than requiring complex post-processing or relying on post-deposition curing.
3Reliability
If shear rate and temperature are controlled to customize material properties, then the strength and performance are enhanced, but the device complexity increases
Solution Approach 1:
The patent achieves universality by using a single extrusion-based additive manufacturing system that can control multiple material properties through shear rate and temperature adjustment. The same extrusion mechanism that deposits material also controls molecular orientation and crystallinity, eliminating the need for separate specialized equipment for each function. This multi-functional approach enhances reliability of material properties while avoiding the complexity of multiple dedicated systems.
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 precise customization of material properties at the molecular level, enhancing the strength and performance of 3D printed objects by controlling shear rate and temperature, allowing for objects with varying properties in the same geometry.
Implementation Method 1
a heater or heaters in communication with the feeder, and the heaters are configured to receive the object material from the feeder for controlled heating of the object material
Implementation Method 2
a shear rate tuning mechanism configured for controlling a shear rate imposed on the object material in one or more directions as the object material passes through the additive manufacturing system
Implementation Method 3
Fused deposition and micro-precision extrusion are additive manufacturing processes that create 3D product architectures by depositing molten polymer strands
Implementation Method 4
a temperature control mechanism for tuning the melt temperature and solidification of the object material throughout the additive manufacturing system
Data Source
AI summary
Described herein are additive manufacturing systems and methods for printing 3D objects.