Shear-Thinning Pseudoplastic 3D Printing Without Supports
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Solution Overview
Problem
Current 3D manufacturing techniques are inefficient for producing large, complex structures like cantilever objects without support structures, requiring extensive manual labor and materials, and lack flame retardancy, posing safety hazards in indoor locations.
Innovation Solution
A method using shear-thinning pseudoplastic materials with flame retardant properties, which are agitated to decrease viscosity for extrusion and then solidify, allowing for the creation of complex structures like cantilever objects without support, using a system with an extrusion unit and UV curing, and a composition comprising curable oligomers, reactive diluents, rheology modifiers, and flame retardants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If large size physical objects are manufactured as shells or hollow structures to save material costs, then material consumption is reduced, but the objects require multiple support structures to prevent warping or collapse
Solution Approach 1:
The patent changes the material parameter from conventional resin to shear-thinning pseudoplastic material, which allows the material to be extruded in a fluid state and then spontaneously form stable structures without support. This parameter change eliminates the need for support structures while maintaining hollow shell geometry
Solution Approach 2:
The pseudoplastic material exhibits self-supporting properties through its shear-thinning behavior and gravitational settling characteristics. The material automatically forms stable structures without requiring external support elements, making the system self-sufficient
2Ease of manufacture
If conventional materials are used for 3D manufacturing, then the process is simpler, but the manufactured objects lack flame retardancy posing safety hazards in indoor locations
Solution Approach 1:
The patent uses composite materials by incorporating flame retardant additives into the pseudoplastic material formulation. This creates a multi-functional material that maintains ease of manufacture while adding fire safety properties, resolving the contradiction between simplicity and safety
3Manufacturing precision
If traditional additive manufacturing methods are used for complex structures like cantilever objects, then support structures are required, but this increases manual labor and manufacturing time
Solution Approach 1:
By changing the material parameters to use shear-thinning pseudoplastic material with specific rheological properties, the patent enables direct printing of complex structures without supports. This parameter change allows higher printing speeds while maintaining structural integrity of complex geometries
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 rapid and cost-effective production of complex, large-scale 3D structures without support, enhancing mechanical strength and safety by incorporating flame retardant properties, reducing material usage and labor, and ensuring structural integrity and fire safety.
Implementation Method 1
agitating the material to shear the pseudoplastic material thereby decreasing viscosity
Implementation Method 2
illuminating the first extruded portion to harden the pseudoplastic material
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3C
AI summary
The current three-dimensional object manufacturing technique relies on the deposition of a pseudoplastic flame retardant material in gel aggregate state. The gel flows through a deposition nozzle because the applied agitation and pressure shears the bonds and induces a breakdown in the material elasticity. The elasticity recovers immediately after leaving the nozzle, and the gel solidifies to maintain its shape and strength.