Silicone Deposition Mixing and Curing for Complex Elastomeric Structures
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Solution Overview
Problem
Existing additive manufacturing systems for elastomeric materials, particularly silicone, face challenges in achieving smooth, consistent texture and desired material properties, are limited to monolithic structures, and struggle with gravity effects, making it difficult to produce medical-grade silicone articles with varying properties and complex shapes.
Innovation Solution
A system comprising a first dispensing system, secondary dispensing system, and deposition apparatus that allows for controlled deposition of elastomeric materials with varying properties, using a dynamic mixer and deposition substrate to overcome gravity effects and enable precise, continuous deposition of filaments or layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If low viscosity, low-temperature-curing materials are used to enable the deposition process, then the deposition process is facilitated, but the structural quality and material properties of the final product are compromised
Solution Approach 1:
The patent applies parameter changes by transitioning from low-temperature curing materials to high-temperature curing materials (e.g., silicone curing at 70-200°C or higher). The system incorporates temperature control mechanisms in the deposition apparatus and curing chamber to manage the higher curing temperatures, thereby achieving both smooth deposition and high structural quality with medical-grade silicone materials.
Solution Approach 2:
The patent implements preliminary action through pre-heating the deposition substrate and maintaining controlled environmental conditions before material deposition. The system pre-configures the curing chamber temperature and prepares the substrate surface to ensure optimal adhesion and curing when high-temperature curing materials are deposited, preventing defects before they occur.
2Reliability
If medical-grade silicone materials are used to achieve desired strength and biocompatibility, then material properties are improved, but the materials are thick and viscous requiring high pressure injection that causes deformation, sagging, or loss of shape before curing
Solution Approach 1:
The patent applies anti-weight principle by using support structures, molds, or temporary fixtures during the deposition and curing process to counteract gravity's effect on viscous silicone material. The system incorporates heating elements that reduce material viscosity locally, and structural supports that prevent sagging and deformation until the material cures and gains strength.
Solution Approach 2:
The patent implements preliminary action by pre-heating the silicone material to reduce its viscosity before deposition, and by preparing pre-heated molds or substrates with appropriate surface treatments. The system also pre-configures support structures and curing conditions to ensure the material maintains its intended shape during the critical curing phase, preventing deformation before the material sets.
3Ease of manufacture
If existing additive manufacturing systems are used to deposit elastomeric material, then material deposition is achieved, but only monolithic structures with uniform properties can be produced
Solution Approach 1:
The patent applies segmentation by dividing the single material deposition system into multiple independent material delivery systems. Each system can deposit different elastomeric materials or materials with different properties (e.g., different Shore hardness, different curing rates). The deposition apparatus includes multiple nozzles or interchangeable nozzle systems that can be positioned to deposit materials in specific spatial patterns, enabling the creation of multi-material structures with regionally varying properties.
Solution Approach 2:
The patent implements dynamics through a programmable deposition system that can dynamically switch between different materials, deposition rates, and nozzle configurations during the manufacturing process. The system uses computer-controlled mechanisms to adjust material flow rates, heating temperatures, and nozzle positions in real-time, allowing the creation of structures with spatially and temporally varying material properties based on digital design specifications.
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 elastomeric articles with controlled material properties and smooth, continuous deposition, overcoming gravity effects and allowing for complex shapes and varying material properties, suitable for medical-grade silicone applications.
Implementation Method 1
The deposition apparatus may comprise a dynamic mixer that blends the material, which may comprise two or more components or separate parts blended before being deposited
Implementation Method 2
The deposition substrate may be arranged to counteract the effects of gravity on the deposited material, thereby keeping it in a desired dimensional state as it cures
Implementation Method 3
The deposition substrate may comprise heat transfer components for tailoring the cure rate of the deposited material and improving the process of deposition
Implementation Method 4
Silicone is a thermoset polymeric material and will cure into its given shape of a strong, dimensionally stable and heat- and chemical-resistant article
Data Source
AI summary
A system for additive manufacturing a medical device, the system comprising a first dispensing system, a second dispensing system, a deposition apparatus, and a deposition substrate on a surface of which the deposition apparatus is configured to deposit at least one elastomeric material into a filament. The deposition apparatus receives the at least one elastomeric material from the first and second dispensing systems in proportions effecting a desired property in the medical device. The deposition apparatus may comprise heating and/or cooling elements, a sonic vibration module, and/or a pneumatic suck-back valve. The deposition substrate may have a configuration corresponding to a desired shape of the medical device and is configured to rotate and/or translate relative to the deposition apparatus. The system comprises a controller configured to control the deposition.