Slurry Repellant Layer and Ultrasonic Agitation for Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing techniques face challenges when working with thin or highly viscous slurries, as they require high forces to achieve the necessary layer thickness, which can damage the object being formed or prevent proper curing due to radiation absorption and penetration issues.
Innovation Solution
A slurry repellant layer, such as polytetrafluoroethylene (PTFE), is applied to the substrate, allowing for easier pushing of the object into the slurry and agitation to reduce the force required, combined with an agitator system like ultrasonic vibration to facilitate thin layer formation and curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high force is applied to push the object into the slurry to achieve necessary layer thickness, then the layer thickness can be controlled, but the object being formed may be damaged
Solution Approach 1:
A slurry repellant layer is introduced as an intermediary between the substrate and the slurry. This layer reduces the friction and adhesion between the slurry and substrate, allowing the object to be pushed into the slurry with significantly reduced force, thereby preventing damage to the object while still achieving the desired layer thickness
Solution Approach 2:
Agitation is applied to the slurry during the pressing process. This mechanical vibration reduces the viscosity of the slurry and facilitates its flow, allowing the object to be pushed into the slurry with less force while maintaining proper layer thickness and distribution
2Reliability
If thin layers of slurry are used to allow radiation penetration for curing, then proper curing can be achieved, but high force is required to push the object into the slurry
Solution Approach 1:
The slurry repellant layer serves as a mediator that reduces the friction between the substrate and the thin slurry layer. This allows the object to be pushed into the thin slurry layer with reduced force, making it feasible to use thin layers for proper radiation penetration and curing without requiring excessive pressing force
Solution Approach 2:
Agitation of the slurry during pressing reduces its viscosity and facilitates flow into the thin layer configuration. This enables the formation of thin slurry layers that can be properly cured by radiation while requiring minimal pressing force
3Stability of the object's composition
If highly viscous slurry compositions are used to achieve desired material properties, then the slurry can be used for manufacturing, but high force is required to push the object into the slurry
Solution Approach 1:
Agitation is applied to the highly viscous slurry during the pressing process. This mechanical vibration temporarily reduces the slurry's viscosity, allowing the object to be pushed into the slurry with reduced force while maintaining the desired slurry composition and material properties
Solution Approach 2:
The slurry repellant layer acts as an intermediary that reduces friction between the substrate and the viscous slurry. This allows the object to be pushed into the highly viscous slurry with significantly reduced force compared to pushing directly into the slurry without the repellant layer
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
This method enables the creation of high-quality three-dimensional objects by reducing the risk of damage and ensuring thorough curing of thin, highly viscous slurry layers, even with radiation-absorbing materials, by minimizing the force needed to form each layer and enhancing slurry agitation.
Implementation Method 1
a slurry repellant layer 3 is provided on a surface of the substrate... the slurry repellant layer 3 has the effect that the slurry can be pushed away more easily
Implementation Method 2
an agitator system arranged to agitate the predetermined amount of slurry... combined with an agitator system like ultrasonic vibration
Implementation Method 3
curing the layer onto the object being formed... exposure unit arranged to cure a layer of slurry
Data Source
Figure 1~2
AI summary
Additive manufacturing apparatus for providing a three dimensional object, and method for additive manufacturing of a three dimensional object (5). An exposure unit (11) is arranged to cure a layer of slurry onto an object (5) being formed, and a substrate (2) is arranged to receive a predetermined amount of slurry (4) and to position the predetermined amount of slurry (4) to an exposure position associated with the exposure unit (11). The substrate (2) comprises a slurry repellant layer (3) on a surface of the substrate (2). An object holder is provided for holding the object (5) being formed, and the object holder is arranged to press the object (5) being formed towards the substrate (2) into the predetermined amount of slurry (4) until a desired thickness of the layer for a next additive manufacturing step is reached.